CTS 4.8 Flex Owner s Manual

Transcription

1 CTS 4.8 Flex Owner s Manual Manufactured Exclusively for HydraMaster th Avenue West Mukilteo, Washington MAN Rev. B, June 30, 2015 (P/N ) No part of this manual may be reproduced or used in any form or by any means (i.e. graphic, electronic, photocopying or electronic retrieval systems) without the express written permission of Harris Research Inc. Specifications and information in this document are subject to change without prior notice. All rights reserved Harris Research Inc.

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3 Table of Contents GENERAL INFORMATION... SECTION 1-1 Contact Information Warnings, Cautions and Notices Machine Specifications - CDS Machine Specifications - Flex Assemblies Responsibilities Hard Water Precautions Waste Water Disposal Advisory OPERATING INSTRUCTIONS... SECTION 2-1 Dash Panel and Instrumentation Panel Before Operating the CTS 4.8 Flex CTS 4.8 Flex Start-Up CTS 4.8 Flex Shut-Down Speed Throttle Control Function FREEZE GUARDING... SECTION 3-1 Freeze Guarding the Flex System CHEMICAL SYSTEM... SECTION 4-1 WATER PUMP MAINTENANCE... SECTION 5-1 Daily Maintenance Periodic Maintenance Water Pump Troubleshooting VACUUM BLOWER SYSTEM... SECTION 6-1 Recovery Tank Inlet Filter Vacuum Blower Lubrication Vacuum Blower Troubleshooting ELECTRICAL SYSTEM... SECTION 7-1 CTS 4.8 Flex Electrical Troubleshooting i - CTS 4.8 Owner s Manual

4 ASSEMBLIES AND PARTS LISTS... SECTION 8-1 Top Level Assembly Parts List Recovery Tank Assembly Parts List Power Pack Assembly Parts List Blower Assembly Parts List Pump Assembly Parts List Frame Assembly Parts List Coolant Heat Exchanger Assembly Parts List Blower Heat Exchanger Assembly Parts List Cross Kit Assembly Parts List Dash Box Assembly Parts List Dash Panel Assembly Parts List Dual Heat Exchanger Assembly Parts List Instrument Panel Assembly Parts List By-Pass Valve Assembly Parts List Hi-PSI Manifold Assembly Parts List Differential Valve Assembly Parts List Recovery Tank Cover Assembly Parts List Vacuum Relief Valve Assembly Parts List Water Box Assembly Parts List Diffuser Filter Assembly Parts List Yaw Sensor Cooling Kit Parts List Pass Through Assembly Parts List Chevy Cowling Assembly Parts List Driver Side Pump Kit Assembly Parts List Passenger Side Pump Kit Assembly Parts List Pump Flex Assembly Parts List Gallon Tank Flex Kit Assembly Parts List Gallon Tank Flex Assembly Parts List Gallon and 15 Gallon Tank Kit Assembly Parts List Gallon and 15 Gallon Tank Flex Assembly Parts List Gallon Tank Solo Flex Assembly Parts List Gallon Tank Flex Assembly Parts List Gallon Tank Flex Chemical Caddy Assembly Parts List Gallon Tank Flex Chemical Caddy Assembly Parts List Quick Connect Dash Box Flex Assembly Parts List By-Pass Valve Flex Assembly Parts List Dura-Flow Automatic Pump Out (APO) Assembly Parts List CTS 4.8 Owner s Manual - ii

5 APO Pump Parts List Pump Cover Flex Assembly Parts List Flex Install Kit Assembly Parts List Wire Harness Flex Assembly Parts List CDS Hose Routing List Flex Hose Routing List MACHINE MAINTENANCE... SECTION 9-1 Operational Maintenance Appearance Maintenance Van Long-Term Maintenance Schedule Drive Shaft Maintenance Troubleshooting Descaling Flex System as Required Back flushing Heat Exchangers Clean QC Dash Box Filters and Orifices Pump Tuning Instructions HOW TO ORDER PARTS... SECTION10-1 Warranty Parts Orders Parts Orders Emergencies WARRANTY INFORMATION... SECTION 11-1 Blower High Pressure Water Pump Recovery Tank Chemical System Control Panel Vacuum and Solution Hoses Cleaning Wand and Tool Water Heating System Hard Water Deposits Warranty Procedure iii - CTS 4.8 Owner s Manual

6 List of Figures and Tables Figure 1-1. CDS Components Figure 1-2. A Flex System Showing 35/15 Gallon Tank Assembly and 50 Gallon Tank Assembly Figure 2-1. CTS 4.8 Flex Dash Panel and Instrumentation Panel Figure 2-2. CTS 4.8 Flex Dash Panel Figure 2-3. CTS 4.8 Flex Instrumentation Panel Figure 2-4. CTS 4.8 Flex Vacuum, Solution and Garden Hose Connections Figure 2-5. Flex Pump Levers Figure 2-6. For 50 Gallon/Tank Assembly: Turn Lever to Tank Drain Hose or in Direction of Pump Strainer Figure 2-7. For 35 Gallon/15 Gallon Tank Assembly: Turn Levers in Direction of Pump Strainer or to Tank Drain Hose Figure 2-8. Switches on Dash Panel Figure 2-9. Press NATURAL PUMP Switch to Middle OFF Position Figure Attach Hose to Discharge Outlet Figure Location of Controller s LEDs and Potentiometers Figure 4-1. CTS 4.8 Flex Flow Diagram Figure 7-1. CTS 4.8 Flex Electrical Schematic Figure 7-2. CTS 4.8 Flex Wiring Diagram - View 1 of Figure 7-3. CTS 4.8 Flex Wiring Diagram - View 2 of Figure 8-1. Adhesive and Sealant Material Reference Figure 8-2. Top Level Assembly - View 1 of Figure 8-3. Top Level Assembly - View 2 of Figure 8-4. Top Level Assembly - View 3 of Figure 8-5. Top Level Assembly - View 4 of Figure 8-6. Recovery Tank Assembly - View 1 of Figure 8-7. Recovery Tank Assembly - View 2 of Figure 8-8. Recovery Tank Assembly - View 3 of Figure 8-9. Recovery Tank Assembly - View 4 of CTS 4.8 Owner s Manual - iv

7 Figure Power Pack Assembly - View 1 of Figure Power Pack Assembly - View 2 of Figure Blower Assembly Figure Pump Assembly - View 1 of Figure Pump Assembly - View 2 of Figure Frame Assembly Figure Coolant Heat Exchanger Assembly Figure Blower Heat Exchanger Assembly Figure Cross Kit Assembly Figure Dash Box Assembly Figure Dash Panel Assembly Figure Dual Heat Exchanger Assembly Figure CDS Heat Exchanger Core Assembly - Product Support Figure Instrument Panel Assembly - View 1 of Figure Instrument Panel Assembly - View 2 of Figure By-Pass Valve Assembly Figure Hi-PSI Manifold Assembly Figure Differential Valve Assembly Figure Recovery Tank Cover Assembly Figure Vacuum Relief Valve Assembly Figure Water Box Assembly - View 1 of Figure Water Box Assembly - View 2 of Figure Diffuser Filter Assembly Figure Yaw Sensor Cooling Kit Assembly Figure Pass Though Assembly Figure Chevy Cowling Assembly Figure Driver Side Pump Kit Assembly Figure Passenger Pump Kit Assembly Figure Pump Flex Assembly Figure Gallon Tank Flex Kit Assembly Figure Gallon Tank Flex Assembly Figure Gallon and 15 Gallon Tank Kit Assembly Figure Gallon and 15 Gallon Tank Flex Assembly Figure Gallon Tank Solo Flex Assembly Figure Gallon Tank Flex Assembly Figure Gallon Tank Flex Chemical Caddy Assembly Figure Gallon Tank Flex Chemical Caddy Assembly Figure Quick Connect Dash Box Assembly Figure By-Pass Valve Flex Assembly Figure Dura-Flow Automatic Pump Out (APO) v - CTS 4.8 Owner s Manual

8 Figure APO Pump Figure Pump Cover Flex Assembly Figure Flex Install Kit Assembly Figure Wire Harness Flex Assembly Figure 9-1. Zerk Fittings on Drive Shaft Figure 9-2. Disconnect Female QC Fitting Assembly with 18 Hose Attached Figure 9-3. Set Pressure, and Connect Solution Hose and Garden Hose Figure 9-4. Remove Orifices from Fittings Figure 9-5. Remove Filter from Fitting Figure 9-6. Location of Pump s Hex Screw Figure 9-7. Connect Solution Hose to QC Dash Box Figure 9-8. CTS 4.8 Flex Dash Panel Showing Pump Switch Position for Pump # Figure 9-9. Disconnect Solution Hose Figure CTS 4.8 Flex Dash Panel, Showing Pump Switch Position for Pump # Figure Insert Hex L-Key and Turn It Counterclockwise/Clockwise Table 2-1. GM Throttle Controller LED Functions CTS 4.8 Owner s Manual - vi

9 1 - General Information The CTS 4.8 Flex is manufactured exclusively for ChemDry by HydraMaster. The configuration* integrates HydraMaster s popular and durable CDS with the specially designed Flex System which dispenses ChemDry s proprietary solutions for carpet and upholstery cleaning. The CDS has been purposely modified to control the Flex System, ensuring that the two systems work seamlessly with each other. FLEX SYSTEM CDS *This is a typical CTS 4.8 Flex configuration and may not represent your current configuration. If hard surface cleaning is required, the CTS 4.8 Flex can be temporarily converted to a CDS, eliminating the need to purchase additional cleaning equipment. 1-1: General Information

10 The CTS 4.8 Flex includes the CDS s recovery tank and power pack which are installed toward the front of Chevy van. The silencer is installed under the van (see Figure 1-1). RECOVERY TANK SILENCER POWER PACK Figure 1-1. CDS Components For more information concerning the CDS, refer to HydraMaster s webpage The CDS Owner s Manual can be found at: General Information: 1-2

11 The typical Flex System includes two tank assemblies, two diaphragm pumps, a canisterstyle coolant heat exchanger and a Salsa-style blower heat exchanger (see Figure 1-2). 35/15 GALLON TANK ASSEMBLY BLOWER HEAT EXCHANGER 50 GALLON TANK ASSEMBLY COOLANT HEAT EXCHANGER Figure 1-2. A Flex System Showing 35/15 Gallon Tank Assembly and 50 Gallon Tank Assembly The 50 gallon tank assembly can be installed at the rear of the van on the driver s side; if the 35 gallon/15 gallon tank assembly is included, it can be installed at the rear of the van on the passenger s side. 1-3: General Information

12 This Owner s Manual provides operating instructions as well as information required for proper maintenance and troubleshooting of the CTS 4.8 Flex. In addition, assembly illustrations and parts ordering information are included for your convenience. It is the purpose of this Manual to help you properly understand and maintain your CTS 4.8 Flex system. Follow the directions and maintenance recommendations carefully, and you will be rewarded with years of profitable, trouble-free operation. It is imperative that no section be overlooked when preparing for operation of this equipment. Please read this Owner s Manual to familiarize yourself with the operation of the CTS 4.8 Flex System, paying special attention to all Warnings and Cautions. This section of the manual contains the following helpful information: Contact Information Warnings, Cautions And Notices Machine Specifications - CDS Machine Specifications - Flex Assemblies Responsibilities Hard Water Precautions Waste Water Disposal Advisory General Information: 1-4

13 CONTACT INFORMATION If you have any questions regarding the operation, maintenance or repair of this machine, please contact your local distributor. When calling your distributor, be sure to reference the serial number and date of purchase. FOR YOUR REFERENCE: Serial No. Date of Purchase: Purchased From (Distributor): 1-5: General Information

14 WARNINGS, CAUTIONS AND NOTICES HydraMaster uses this WARNING symbol throughout the manual to warn of possible injury or death. This CAUTION symbol is used to warn of possible equipment damage. This NOTICE symbol indicates that federal or state regulatory laws may apply, and also emphasizes supplemental information. General Information: 1-6

15 Warnings and Cautions specific to the CTS 4.8 Flex include: HOT SURFACES: During the operation of this equipment, many surfaces on the machine will become very hot. When you are near the van for any reason, care must be taken not to touch any hot surface, such as the engine or the exhaust. If this warning is not heeded, personal injury or death can result. HEARING PROTECTION: The Occupational Safety and Health Administration (OSHA) recommends the use of hearing protection when a technician is exposed to an average of 85 decibels (this is an average of exposure over an 8 hour period). This equipment can produce 85 decibels to a distance of 10 feet. Please check with your local state agencies to see if OSHA standards apply to your application. NO SMOKING: It is unsafe to smoke in or around the vehicle. Do not allow any open flames in or around the vehicle. CARBON MONOXIDE: This unit generates toxic fumes. Position the vehicle so that the fumes will be directed away from the job site. Do not park where exhaust fumes can enter a building through open doors, windows, air conditioning units or kitchen fans. TOXIC FUMES: Do not occupy the vehicle when the cleaning equipment is operating. Toxic fumes may accumulate inside a stationary vehicle. ENGINE EXHAUST: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. MOVING PARTS: Never touch any part of the machine that is in motion. Severe bodily injury may result. 1-7: General Information

16 The use of some chemicals through your mobile carpet cleaning plant can seriously damage the internal plumbing, high-pressure pump, chemical pump and heat exchangers. These harmful chemicals include concentrated acid, solvents (including d-limonene), and some paint, oil and grease removers with a high concentration of solvents. THROUGH-FLOOR DRILLING: Be cautious when drilling holes through the van floor. Many vans have critical components mounted directly below the van floor that could be damaged by a misplaced drill bit. LEVEL OPERATION: During operation, the vehicle must be parked on level ground not to exceed + or - 10 degrees. Failure to ensure proper leveling may prevent proper internal lubrication of engine, vacuum and/or high pressure components. ACID RINSE AGENTS: Some acid rinse products can cause damage to internal machine components. Failure to take appropriate measures to prevent acidic corrosion can result in system failure and loss of warranty on affected parts. HARD WATER PROTECTION: Failure to take appropriate measures to prevent scale build up can result in system failure and loss of warranty on affected parts. Test the water in your immediate and surrounding areas with hard water test strips. Assume all water obtained from wells is hard. If you are operating in a hard water area at 3.0 grains or more per gallon, use a water softening system. FREEZE PROTECTION: Failure to take appropriate measures to prevent equipment damage due to freezing can result in system failure and loss of warranty on affected parts. Placing an electric heater in the vehicle or parking the vehicle indoors will help ensure against freezing, but should not be the primary method of freeze protection. HOT SURFACES: During the operation of this equipment, surfaces, ranging from the heat exchangers to the solution ports, will become hot. Do not allow components such as hoses to touch hot surfaces. Failure to heed this warning can result in equipment damage which is not covered by warranty. General Information: 1-8

17 MACHINE SPECIFICATIONS - CDS Frame 23 W x 41.5 H x 61.0 L Weight 912 lbs. Construction Tank Marine Aluminum with Baked-on Epoxy Finish Chassis, Painted Steel Cowling, Fiberglass Power Transfer Electric Clutch-driven shaft, Key Activated Vacuum Blower 4007 Tuthill/M-D Tri-Lobe Water Pump Plunger Pump, 4.0 gpm (at high speed), 1,200 psi, Electric Clutch Control Heating System Multiple Heat Exchangers (1,200 psi pressure) Dual Shell and Tube Exchanger, Coolant Heat Exchanger, Blower Heat Exchanger Dash Assembly Panel Electronic Tachometer, 0-3,000 rpm Water Temperature Gauge, Degrees F Vacuum Gauge, 0-30 Hg Hour Meter, Machine Run-Time Keyed Ignition, Start/Stop Electronic Circuit Protection Breaker, Re-settable Machine Status Indicator LEDs Instrumentation Assembly Panel Water Pressure Adjustment Water Pressure Gauge, Liquid Filled, 0-1,500 psi Blower Lubrication Port Water Temperature Adjustment Knob Water Box Drain Valve Recovery Tank 100 gallon Aluminum 1-9: General Information

18 MACHINE SPECIFICATIONS - FLEX ASSEMBLIES 50 Gallon Tank Dimensions 12 W x 33 H x 60 L with Frame Weight 113 lbs 35/15 Gallon Dimensions 12 W x 33 H x 53 L Tanks with Frame Weight 108 lbs Construction Frames Steel Tanks Polyethylene General Information: 1-10

19 TYPICAL CONFIGURATION EQUIPMENT Coolant Heat Exchanger Cowling - Chevy CDS Gray Dash Box - QC Power Pack - Blower Assembly, Water Pump Assembly and Frame Assembly Flex Tank Frames and Assemblies with Passenger Side Pump and Driver Side Pump Recovery Tank Blower Heat Exchanger Front End - Chevy Silencer Wheel Chock Set 125 ft Solution Hose 50 ft, 2" Vacuum Hose Owner s Manual (on CD) Owner s Guide (hardcopy) OPTIONAL EQUIPMENT Automatic Pump Out (APO) Rear Door Kits 1-11: General Information

20 RESPONSIBILITIES Prior to the arrival of the unit, the van that it will be installed in should be delivered to the installer. Purchaser s Responsibility If you are the purchaser, it is the your responsibility to read the Owner s Manual and to familiarize yourself with the information contained herein, paying special attention to all Warnings and Cautions. Sales Representative s Responsibility Acceptance of Shipment 1. If the unit shows any outward signs of damage, do not sign the delivery receipt until you have closely inspected the unit and noted any damage on the delivery receipt. 2. The sales representative from whom you purchased your unit is responsible for supervising the correct installation of the unit in your vehicle and thoroughly training you in its operation, maintenance and precautions. Installation Correctly installing the unit and recovery tank in your vehicle and securing them with bolts and tie down washers. Checking the pump, vacuum blower and engine oil levels prior to starting the unit. Starting the unit to check the drive system and see that all other systems function normally. Checking all hoses, tools/wands and accessories for correct operation. Training A thorough review of the Owner s Manual with the purchaser. Instruction in and familiarization with: 1. How to correctly start up and shut down the unit 2. How to correctly clean with the unit 3. Where and how often to check and change component oil levels 4. How the unit s systems work, how to troubleshoot the unit 5. How to do basic repairs 6. Safety precautions and their importance 7. How to avoid freezing damage 8. How to avoid hard water damage A thorough review of the unit warranty and warranty procedures. A thorough review of hard water precautions and warnings. How to determine hard water areas. Use of water softening systems. General Information: 1-12

21 HARD WATER PRECAUTIONS Consult your local ChemDry distributor about recommendations for dealing with hard water conditions in your area before adding water to the Flex tanks. WASTE WATER DISPOSAL ADVISORY There are laws in most communities prohibiting the dumping of recovered gray water from carpet cleaning in any place but a sanitary treatment system. The cleaning solution, recovered into your unit s recovery tank, contains materials that must be safely processed before entering streams, rivers and reservoirs. In most cases, an acceptable method of waste water disposal is to discharge into a municipal sewage treatment system after first filtering out solid material such as carpet fiber. Access to the sanitary system can be obtained through a toilet, laundry drain, RV dump, etc. Permission should first be obtained from any concerned party or agency. One disposal method which usually complies with the law is to accumulate the waste water and haul it to an appropriate dump site. Another solution to the disposal problem is to equip your CDS with an Automatic Pump-Out System (APO). These systems are designed to remove waste water from the extractor s recovery system and actively pump the water through hoses to a suitable disposal drain. HydraMaster makes an APO System which can be ordered with new equipment or installed later. When properly configured, the systems will continuously monitor the level of waste water and pump it out simultaneously with the cleaning operation. The hidden benefit of this process is that the technician does not have to stop his/her cleaning to empty the recovery tank. IN ACCORDANCE WITH EPA, STATE AND LOCAL LAWS, DO NOT DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC. The penalties for non-compliance can be serious. Always check local laws and regulations to be sure you are in compliance. 1-13: General Information

22 General Information: 1-14

23 2 - Operating Instructions This section describes how to properly start up, operate and shut down the CTS 4.8 Flex, starting with a description of the Dash Assembly and Instrumentation Panel Assembly (see Figure 2-1). VACUUM INLETS DASH PANEL INSTRUMENTATION PANEL QC DASH BOX Figure 2-1. CTS 4.8 Flex Dash Panel and Instrumentation Panel 2-1: Operating Instructions

24 DASH PANEL AND INSTRUMENTATION PANEL The CTS 4.8 Flex Dash Assembly, shown in Figure 2-2, controls the: System s power on/off and throttle control Flex pumps - also called Natural Pump 1 (Driver s Side) and Natural Pump 2 (Passenger s Side) Automatic Pump-Out (APO) if included in the configuration TEMPERATURE GAUGE TACH (RPM) GAUGE VACUUM GAUGE HOUR METER STATUS LEDS RESET BUTTON Figure 2-2. CTS 4.8 Flex Dash Panel The Dash Assembly also includes the temperature, tach and vacuum gauges; status LEDs, the hour meter, and the reset button. When the status LEDs on the left of the dash are lit, they indicate that: Vacuum Tank (recovery tank) - tank is full and should be emptied. Pump Out - APO is operating Low Water - water in the water box is low Operating Instructions: 2-2

25 The reset button will pop out if your machine encounters any shut down condition, such as an electrical short in the system. If the button pops out, troubleshoot and fix the problem(s) before trying to reset the machine (by pressing the button). BLOWER LUBRICATION PORT The Instrumentation Panel Assembly shown in Figure 2-3, includes the: Blower lubrication port Coolant flow lever (temperature control) COOLANT FLOW LEVER Figure 2-3. CTS 4.8 Flex Instrumentation Panel 2-3: Operating Instructions

26 BEFORE OPERATING THE CTS 4.8 FLEX 1. Locate the van and equipment in a well-ventilated area. The CTS 4.8 Flex generates toxic fumes. Position the vehicle so that the fumes will be directed away from the job site. Do not park where exhaust fumes can enter a building through open doors, windows, air conditioning units or kitchen fans. If this warning is not heeded, personal injury and death can result. 2. Check the fuel tank to be certain there is adequate fuel to complete the job. 3. Position the wheel chocks in front of/behind one of the front tires. 4. Connect the solution hose(s) to the Quick Connect (QC) Dash Box (see Figure 2-4). 5. Connect the vacuum hose to the vacuum inlet as shown in Figure 2-4. Make sure the recovery tank drain valve is closed when operating the machine. IN ACCORDANCE WITH EPA, STATE AND LOCAL LAWS, DO NOT DISPOSE OF WASTE WATER INTO GUTTERS, STORM DRAINS, STREAMS, RESERVOIRS, ETC. The penalties for non-compliance can be serious. Always check local laws and regulations to be sure you are in compliance. Operating Instructions: 2-4

27 CONNECT VACUUM HOSE HERE CONNECT SOLUTION HOSES MAKE SURE RECOVERY TANK DRAIN VALVE IS CLOSED WHEN OPERATING CTS 4.8 FLEX Figure 2-4. CTS 4.8 Flex Vacuum, Solution and Garden Hose Connections 2-5: Operating Instructions

28 6. Make sure the 3-way ball valve levers are all in the downward or vertical position (see Figure 2-5). The levers on the Flex pumps control the direction of the chemical flow. When the levers are in the vertical position, the flow is turned OFF. 3-WAY BALL VALVES LEVER LEVER Figure 2-5. Flex Pump Levers 50 GALLON TANK To Tank Drain Hose To Pump Strainer LEVER Figure 2-6. For 50 Gallon/Tank Assembly: Turn Lever to Tank Drain Hose or in Direction of Pump Strainer 7. Open the Flex chemical tank lid(s) and fill the chemical tank(s) with appropriate ChemDry chemical until the chemical levels off below the tank vent hose hole. Operating Instructions: 2-6

29 There are 2 levers on the 35 Gallon/15 Gallon Tank Assembly, one for each tank (see Figure 2-5). There is 1 lever located on the 3-way ball valve on the 50 Gallon Tank Assembly (see Figure 2-6). Before operating the Flex System, turn the appropriate lever toward the direction of the flow (toward the hose connected to the pump strainer - see Figure 2-6 and Figure 2-7). 15 GALLON TANK To Pump Strainer To Tank Drain Hose LEVER 35 GALLON TANK To Pump Strainer To Tank Drain Hose LEVER Figure 2-7. For 35 Gallon/15 Gallon Tank Assembly: Turn Levers in Direction of Pump Strainer or to Tank Drain Hose To drain the pumps, turn the lever away from the flow. To turn the flow off, turn the levers downward or in the vertical position. 2-7: Operating Instructions

30 CTS 4.8 FLEX START-UP 1. Make sure the vehicle s gear select lever is in the Park position and the emergency brake is set 2. Start the vehicle s engine. 3. Turn the ignition key on the CTS 4.8 Flex dash panel to the ON position (see Figure 2-8). Turn to ON Position Figure 2-8. Switches on Dash Panel 4. Press the THROTTLE CONTROL switch to High, Mid or Low cleaning speed appropriate for the cleaning job. 5. Press the NATURAL PUMP switch to #1 or #2, depending upon which Flex Tank Assembly will be used. 6. Optional: Press the PUMP OUT switch to ON if using the Automatic Pump-Out feature. The PUMP OUT system will not engage until the water level rises inside the recovery tank. 7. Now, proceed with the cleaning operation. The machine will automatically shut down when it reaches its full capacity due to the float switch located inside the recovery tank. When this occurs, turn the NATURAL PUMP switch OFF and empty the recovery tank. Then, turn the unit back on and continue to clean. Operating Instructions: 2-8

31 CTS 4.8 FLEX SHUT-DOWN 1. Turn off the Flex system by pressing the NATURAL PUMP switch to the middle OFF position (see Figure 2-9). 2. Lay vacuum hoses out in order for all moisture to be removed from the hoses. This prevents spillage of any dirty solution in your vehicle when storing the hoses. Figure 2-9. Press NATURAL PUMP Switch to Middle OFF Position 3. Disconnect the hoses and put them away. 4. Allow the unit to run for a few minutes with the vacuum hose disconnected in order to remove all moisture from the vacuum pump. 5. Plug the vacuum inlets. Spray a Hydramaster-recommended lubricant (P/N ) into the blower lube port for about 5 to 7 seconds while the unit is running. This will lubricate the vacuum pump and prevent it from rusting. (The blower lube port is located on the front panel above the pressure gauge - see Figure 2-3). 6. Remove the inlet plugs, then turn the ignition OFF before draining the recovery tank. 7. Turn the COOLANT FLOW LEVER to the OFF position. This will help avoid engine overheat problems due to reduced coolant flow through the radiator. 2-9: Operating Instructions

32 8. If you do not have an APO: Attach a drain hose to the recovery tank drain outlet and open the valve to drain the waste water from the recovery tank (see Figure 2-4). 9. If you have an APO: Attach a drain hose to the recovery tank discharge outlet before draining the waste water (see Figure 2-10). Do not dump waste in any area which might violate local, state or federal law. If you have the optional Automatic Pump-Out (APO) system, drain the recovery tank into a sanitary drain system. Figure Attach Hose to Discharge Outlet 10. After the recovery tank is drained, lift the recovery tank lid up and remove the filter basket. 11. Clean out any accumulated debris. 12. Rinse and re-install. 13. Check the corrugated blower filter. 14. Clean out any accumulated debris. 15. Rinse and re-install. Operating Instructions: 2-10

33 3 SPEED THROTTLE CONTROL FUNCTION The GM Throttle Controller must meet certain Chassis Ready conditions to elevate the engine rpm, which are as follows: 1. Parking Brake is set 2. Gear shift is in Park 3. Foot is off Service Brake (brake pedal) 4. Foot is off Accelerator Pedal 5. Vehicle is stationary (no speed) 6. Engine is started and idling 7. The A/C / Heater switch is in off position The Throttle Controller must be initialized anytime the Data Link Cable (DLC) harness is disconnected from the Data Link Connector. To initialize the system switch ignition key to OFF position, plug in DLC harness, switch the ignition on, and then start the engine. This allows the Throttle Controller to read the PCM engine computer. On the Throttle Controller, there are LED lights with corresponding labels to provide status and problem detection information (refer to Figure 2-11 and Table 2-1). LEDs WITH LABELS 3 TRIM POTS Figure Location of Controller s LEDs and Potentiometers 2-11: Operating Instructions

34 Table 2-1. GM Throttle Controller LED Functions LED STATUS INDICATION BUSS On Solid Unit ON and functioning (harness connected to data link) BUSS Flashing Unit ON, but a problem was detected GEAR On Solid Transmission in PARK GEAR Flashing Transmission NOT in Park PK BRK On Solid Parking Brake Set PK BRK Flashing Parking Brake is NOT set SR BRK On Solid Service Brake is set (not being used) SR BRK Flashing Service Brake is NOT set VSPEED On Solid Vehicle is stationary VSPEED Flashing Vehicle is moving RPM1 On Solid RPM1 mode selected, engine at fast idle RPM1 Flashing RPM1 mode selected, engine not at fast idle RPM2 On Solid RPM2 mode selected, engine at fast idle RPM2 Flashing RPM2 mode selected, engine not at fast idle RPM3 On Solid RPM3 mode selected, engine at fast idle RPM3 Flashing RPM3 mode selected, engine not at fast idle On GM gas engine vehicles, the PCM engine computer will cause the engine speed to momentarily drop back to normal idle speed every time the air conditioner pump cycles on or off. Make sure the operator of the CDS understands that the AC / HEAT switch needs to be in the OFF position before activating the CDS unit. Operating Instructions: 2-12

35 3 - Freeze Guarding When operating the CTS 4.8 Flex during the colder months of the year, ensure that you properly freeze guard the System. No part of the CTS 4.8 Flex is covered by warranty if machine damage occurs because of freezing. BE SURE YOUR MACHINE IS PROTECTED! Freezing will cause component damage. The following precautions are recommended prior to and during cleaning jobs: 1. Run the machine before leaving for the first job to ensure nothing has frozen the night before, including hoses and tool/wand. 2. Insulate the solution hose from the cold ground by running it through an extra 1½ vacuum hose. 3. Leave vehicle doors closed until you begin cleaning; afterwards, open slightly. In colder climates, insulating the vehicle walls and floor boards will help protect the unit. Do not procrastinate during the cleaning operation or the hot water solution line will also freeze on the ground. The solution line should be insulated in extremely cold climates. Whenever possible, store the van in a heated garage at night or over the weekend. If not possible, place a 1,500 Watt electric heater inside the vehicle, aimed directly at the machine. Never use a propane heater. It causes excessive moisture on the vehicle ceiling and the possibility of it malfunctioning is therefore higher, which may cause bodily injury. If the CTS 4.8 Flex and vehicle are left outside with a heater, drain water from the cleaning tools and hoses because they can be freeze damaged also. 3-1: Freeze Guard

36 FREEZE GUARDING THE FLEX SYSTEM 1. Connect a solution line to one of the connectors on the Flex QC Dash Box with the tool of your choice attached at the end. 2. Place the tool into a container to collect the solution from the tool. 3. Pour 2 gallons of 50/50 antifreeze and water into each Flex tank. 4. Turn on Natural Pump # 1 and squeeze the trigger on the tool until antifreeze starts to come out of the tool. 5. Turn on Natural Pump # 2 and squeeze the trigger on the tool until antifreeze starts to come out of the tool. 6. Press the NATURAL PUMP switch to the middle OFF position. Before filling the Flex tanks with chemical and starting the next cleaning job, drain the antifreeze completely from the Flex tanks and run water though the pumps until clear water drains from the machine. WHEN DISPOSING OF USED ANTIFREEZE COOLANT: Follow local laws and regulations. If required, dispose at facilities licensed to accept household hazardous waste. If permitted, dispose in sanitary sewer systems. Do not discard into storm sewers, septic systems, or onto the ground. This warning appears on the label of one brand of antifreeze: HARMFUL OR FATAL IF SWALLOWED. Do not drink antifreeze coolant or solution. If swallowed, induce vomiting immediately. Call a physician. Contains Ethylene Glycol which caused birth defects in animal studies. Do not store in open or unlabeled containers. KEEP OUT OF REACH OF CHILDREN AND ANIMALS. Freeze Guard: 3-2

37 4 - Chemical System The general concept of the CTS 4.8 Flex chemical flow is as follows: Chemical is fed into the CTS 4.8 Flex from the Flex tanks. The chemical is then pumped through the heating system and out to the cleaning tool/ wand. After the solution is applied to the carpet, it is recovered by the vacuum system and carried back to the recovery tank. 4-1: Chemical System

38 Chemical System: 4-2

39 Figure 4-1. CTS 4.8 Flex Flow Diagram Rev. B WATER OUT ORIFICE ORIFICE FILTER V-12 3-WAY PRIMING VALVE 3-WAY CHEMICAL METERING VALVE WATER OUT FILTER BYPASS VALVE WATER IN CHEMICAL COLD WATER ENGINE COOLANT EXHAUST HOT WATER RECOVERED SOLUTION NATURAL SOLUTION HIGH PRESSURE FLUSH CHEMICAL JUG FILTER CHEMICAL PUMP PMP-3 V-2 THERMAL RELIEF VALVE V-7 FLOW METER FL-1 V-4 BYPASS VALVE V-8 WATER IN V-5 WATER BOX DRAIN VALVE PRESSURE GAUGE PI-1 WATER BOX INLET WATER VALVE V-1 FLOAT SWITCH WATER OUT FS-4 HI PRESSURE PUMP 1750 RPM PMP-1 DASH BOX QUICK CHANGE TO ATMOSPHERE 15G TANK TO ATMOSPHERE 3-WAY BALL VALVE 35G TANK TO ATMOSPHERE 3-WAY BALL VALVE V-14 V-13 PMP-4 TO ENGINE FROM ENGINE V-9 COOLANT FLOW VALVE COOLANT HEAT HX-1 EXCHANGER COOLANT HEAT HX-3 EXCHANGER 3,000 PSI V-17 CHECK VALVE CROSS CR-1 V-16 3,000 PSI CHECK VALVE TO ATMOSPHERE FILTER NATURAL PUMP PASSENGER TO ATMOSPHERE FROM WAND VACUUM GAUGE VI-1 INSTRUMENT PANEL 50G TANK 3-WAY BALL VALVE V-15 PMP-5 FLOAT FS-2 SWITCH FS-3 FLOAT SWITCH FILTER FILTER VACUUM BLOWER BLR-1 SALSA HEAT EXCHANGER HX-2 SILENCER SLR-1 V PSI CHECK VALVE WATER OUT V-11 PETCOCK VALVE NATURAL PUMP DRIVER FILTER FS-6 FLOAT SWITCH V-6 WATER OUT TO ATMOSPHERE RECOVERY TANK DRAIN VALVE TI-1 TEMPERATURE SENDER PMP-2 APO PUMP (OPTIONAL) WATER OUT 4-3: Water and Chemical System

40 Water and Chemical System: 4-4

41 5 - Water Pump Maintenance The CDS water pump features a dynamic low-pressure seal retainer, an innovative intermediate ring, and superior low-pressure and high-pressure seals. With its ceramic plungers and nickel-plated forged brass manifold, this high-temperature pump is ideal for use in carpet cleaning. For maintenance information on the Flex pumps, see page 9-2 and 9-3. You must perform daily and periodic maintenance on the CDS water pump to maintain maximum performance of seals and valves. This section of the manual explains: Daily Maintenance Periodic Maintenance Water Pump Troubleshooting DAILY MAINTENANCE 1. Check the oil level and the condition of the oil. The oil level should be up to the center of the sight glass on the back of the pump. 2. Use GP series oil. If the oil becomes discolored and contaminated, one of the oil seals may be damaged. Refer to the Pump Owner s Manual, included with the CD version of the CTS 4.8 Flex Owner s Manual, for more information. Do not operate the pump if the crankcase has been contaminated with water; if contamination occurs, component damage can result. Do not leave contaminated oil in the pump housing or leave the housing empty. Remove contaminated oil as soon as it is discovered and replace it with clean oil; if contamination occurs, component damage can result. 5-1: Water Pump Maintenance

42 Do not turn the drive shaft while the oil reservoir is empty. This can cause component failure. Protect the pump from freezing. Failure to do so can result in component failure which will void warranty coverage. PERIODIC MAINTENANCE Change the oil after the first 50 hours of operation, with the pump stopped and the oil still warm, and after every 300 operating hours or 3 months of operation. When changing the oil, remove the drain plug on the oil drain hose so all oil and accumulated sediment will drain out. The initial oil change is recommended for no other reason than to eliminate impurities that may be in the oil during the running-in phase. If these impurities are not removed, but are allowed to remain in the oil, they may cause premature wear to the moving parts and the oil seals. If the pump works in conditions with high humidity and with sharp temperature changes, condensation may appear inside the crankcase. Condensation mixing with the oil can change the oil s properties, which is easy to detect because the oil changes to a white, milky color. If the pump does not have excessive water leaking from the packings, and the oil becomes milky, the oil has to be changed more frequently. Water Pump Maintenance: 5-2

43 WATER PUMP TROUBLESHOOTING 1.0.Will not come up to normal cleaning pressure POSSIBLE CAUSE SOLUTION 1.1. Pressure adjusting valve Disassemble valve. Repair or replace as necessary. is defective or dirty Worn seals or valves in Test pump output volume directly from pump at normal pump. operating rpm. If volume is below manufacturers specifications, replace seals and inspect for defective valves Pump rpm is too low. Check engine rpm and adjust as necessary. Check for loose pump belt. Adjust tension as necessary Primary system control Remove filter and inspect. Tighten or replace as orifice is missing or loose*. necessary Primary orifice is worn.* Measure orifice size and replace as necessary. *Applies to SALSA option only No pressure reading on PSI gauge POSSIBLE CAUSE SOLUTION 2.1. Pump switch is not Turn on switch turned on No water in water box. Refer to section 4 of this manual Pump belt is broken. Replace belt Pump clutch is not Check system back to source to locate cause of activated. There is no water interruption to water flow. in water box 2.5. Pump clutch is not Check for 12V at clutch. If 12V is present, replace clutch. activated. There is water in the water box. If 12V is not present, check power to the low-water relay. If there is 12V at the relay, check low water switch in water box. If low water switch has no continuity when float is up, replace the switch. If switch is good, replace the low water relay. 5-3: Water Pump Maintenance

44 3.0. PSI gauge reads normal; low pressure from tool/wand POSSIBLE CAUSE SOLUTION 3.1. There is a restriction in Inspect tool jet and clean or replace as necessary. the cleaning tool/wand. Inspect any filters in the cleaning tool and clean or replace as necessary There is a defective Inspect each quick connect and replace as necessary. quick connect in the system There is a restriction in Remove quick connects and inspect hoses. Clean or one of the solution hoses. replace as necessary There are hard water deposits restricting the system between the heat exchanger and the highpressure solution connection at the front of the machine. Descale the machine. If this doesn t solve the problem, disassemble this portion of the system and locate restriction Pressure pulsation POSSIBLE CAUSE 4.1. Water in the water-box is too hot and is approaching boiling point There is an air leak between the water box outlet and the pump inlet One of the intake or outlet valves in the high-pressure pump is defective or is being held open by debris. SOLUTION Check temperature of water in the water-box. Physically check all hoses and fittings for cuts, breaks, cracks or tightness. Repair as necessary. Remove each valve and inspect for correct operation Water box empty or fills slowly POSSIBLE CAUSE SOLUTION 5.1. There is a restriction in Inspect the supply system from the source through the the water supply system. incoming quick connect for kinks, clogs or restricted filters. Clean or repair as necessary The float valve in the Replace. water box is defective Water Pump Maintenance: 5-4

45 6 - Vacuum Blower System This section of the manual covers the CDS vacuum blower system and includes information on: Recovery Tank Inlet Filter Vacuum Blower Lubrication Vacuum Blower Troubleshooting The vacuum blower, featuring tri-lobe rotors, is designed for maximum positive displacement and manufactured using special porting technology to significantly reduce noise. Lubrication for both the gear end and drive end of the blower is provided by full oil splash. Unlike grease lubrication, oil-splash lubrication provides for longer bearing and seal life through improved heat dissipation. At the gear end, the timing gear teeth are lubricated by submersion in oil with the gear teeth serving as oil slingers. At the drive end, the bearings are also lubricated by submersion in oil with oil slingers attached on the shafts. The performance and life of the vacuum blower is greatly dependent on the care and proper maintenance it receives. Because of the close tolerances between the 3 lobes and housing of the vacuum blower, solid objects entering the inlet will damage the internal lobes, gears, bearings or drive system. To prevent this from happening, a stainless steel filter screen has been placed at the vacuum blower intake inside the vacuum recovery tank. This stainless steel filter system should be removed for cleaning on a daily basis. Use caution when the CDS is being run for test purposes and the vacuum inlet is open. Unregulated vacuum may cause injury if body parts come in contact with the open vacuum inlet. 6-1: Vacuum Blower System

46 To protect the vacuum blower from overloading and damaging itself, there is a vacuum relief system installed on the vacuum recovery tank. When the recovery tank inlet is completely sealed off, a maximum of 14 Hg will be attained. At the end of each day, spray the HydraMaster-recommended lubricant (P/N ) into the blower lubrication port before shutting down the machine. If you fail to lubricate the vacuum blower on a daily basis, rust deposits and moisture can form and decrease the life of the vacuum blower. Foam passing through the blower could lead to serious problems. Therefore, it is important to keep the recovery tank foam free. When cleaning surfaces with excessive foaming residue, use HydraMaster s Defoamer as directed. The recovery tank is protected from excessive water level overflowing by a recovery tank float kill switch. The switch is not activated by foam, only by liquid. RECOVERY TANK INLET FILTER HydraMaster inlet filter screens are designed to trap lint, hair and large objects that would normally collect at the bottom of your recovery tank. Clean the screen at the end of each job to eliminate build-up of debris in the tank. VACUUM BLOWER LUBRICATION Read the vacuum blower Owner s Manual for proper oil changing instructions. (A digital copy of the vacuum blower Owner s Manual can be found on the CD which is shipped with each CTS 4.8 Flex Owner s Guide.) Because the CDS is very demanding of the vacuum blower, the vacuum blower should be maintained as recommended in the vacuum blower Owner s Manual. The vacuum blower manufacturer recommends the use of PneuLube (ISO 100) as a lubricant at temperatures ranging from 0 degrees F to 120 degrees F. Vacuum Blower System: 6-2

47 Remember to: 1. Remove fill plugs or breathers from both gear end and drive end plates. 2. SLOWLY pour oil through fill until oil appears in the oil sight glass. Bring oil level to center of sight glass. 3. Verify oil level is at proper level in BOTH gear end and drive end sight glasses. 4. Replace fill plugs or breathers that were removed in step Add fresh oil as required to maintain proper level. The oil should be drained, flushed and replaced every 400 hours. The oil drain hose is connected under the head plate; at the end of the oil drain hose is a cap. 6-3: Vacuum Blower System

48 VACUUM BLOWER TROUBLESHOOTING 1.0. Weak vacuum at tool/wand. Gauge reads normal (10 Hg to 14 Hg) POSSIBLE CAUSE SOLUTION 1.1. Clogged hoses or tool/ Disconnect hoses and carefully check for an obstruction. wand tube Excessive length of hoses connected to machine. Make sure machine is rated for the conditions under which it is being operated Vacuum gauge will not come up to 14 Hg POSSIBLE CAUSE SOLUTION 2.1. There is an air leak Check vacuum relief valve for proper adjustment. Check somewhere in the vacuum all hoses for cuts and breaks. Check recovery tank lid system. gasket. Make sure the recovery tank drain valve is fully closed The vacuum gauge is Test and replace as necessary. defective. 2.3.Vacuum blower is turning too slowly. Check blower rpm at tachometer on the CDS dash. Blower rpm should be 2 times the tachometer rpm. See the throttle control kit instructions for further troubleshooting assistance Vacuum gauge reads high with no hoses attached POSSIBLE CAUSE SOLUTION 3.1. Filter in recovery tank is Remove and clean or replace as necessary. clogged Hose from recovery Inspect and replace as necessary. tank to blower is collapsed internally Vacuum Blower System: 6-4

49 7 - Electrical System Because the most difficult problem to trace in any system is often an electrical failure, HydraMaster has designed the CDS electrical system with the technician in mind. This section of the manual includes troubleshooting guides as well as wiring schematics and diagrams. The entire electrical system operates on 12V DC which is provided by the vehicle s battery. To avoid equipment damage, it is very important to tie up any loose wires or hoses near the drive shaft area. Tie wraps are sufficient for wires and small hoses. When securing large hoses or wiring harnesses in the area of the drive shaft, tie down the components with a hose clamp, with a clear vinyl hose inserted onto the clamp. On some installations, if the fuel injector wires are not properly secured, the wires could rub against the CDS drive shaft causing a short in the electrical system of the van. 7-1: Electrical System

50 CTS 4.8 FLEX ELECTRICAL TROUBLESHOOTING 1.0. CDS will not turn on POSSIBLE CAUSE 1.1. The main power fuse has blown The plug-in connection at the base of the recovery tank is corroded The main circuit breaker has blown on the CDS dash. SOLUTION Remove CDS cowling and engine cover and check all wiring from the power source back to the CDS console for damage. Replace fuse only after locating the problem that caused the fuse to blow. If unable to locate problem, refer to qualified service technician. Clean and seal connection to protect it from moisture. Reset breaker and look for loose connections or damaged wires. Check all wires from the control panel forward to the front of the vehicle. If no problem is found but the breaker still trips refer to qualified service technician CDS shuts off while in use POSSIBLE CAUSE SOLUTION 2.1. Recovery tank is full. Empty tank and restart machine Recovery tank float Inspect float to see if the triangle mark on the float is switch is dirty or defective. facing up. If it is, and the float slides freely on the post, replace the float assembly The vehicle gear selector has moved. Inspect the gear selector to be sure it is in the proper position. If selector has moved, refer to qualified service technician. If vehicle gear selector has moved, refer to qualified service technician - it needs to be repaired immediately. This is a dangerous condition and can cause death or injury. Electrical System: 7-2

51 Figure 7-1. CTS 4.8 Flex Electrical Schematic Rev. A S I Electrical System: 7-3

52 Figure 7-2. CTS 4.8 Flex Wiring Diagram - View 1 of Rev. A S I 7-4: Electrical System

53 Figure 7-3. CTS 4.8 Flex Wiring Diagram - View 2 of Rev. A D D Electrical System: 7-5

54 Electrical System: 7-6

55 8 - Assemblies and Parts Lists This section of the manual provides detailed illustrations and parts lists for the following assemblies. When ordering parts for assemblies, first refer to the appropriate assembly listed here and then find the part number listed on that specific page. In most cases, you do not have to order the entire assembly to get a part. If you have an electronic copy (a.pdf) of this Manual, you can search for the part number by pressing the CTRL key and the F key at the same time. This will pop up the Find window on your monitor. Type the part number, including dashes, into the Find window and press the Enter key. Top Level Assembly Parts List Recovery Tank Assembly Parts List Power Pack Assembly Parts List Blower Assembly Parts List Pump Assembly Parts List Frame Assembly Parts List Coolant Heat Exchanger Assembly Parts List Blower Heat Exchanger Assembly Parts List Cross Kit Assembly Parts List Dash Box Assembly Parts List Dash Panel Assembly Parts List Dual Heat Exchanger Assembly Parts List Instrument Panel Assembly Parts List By-Pass Valve Assembly Parts List Hi-PSI Manifold Assembly Parts List Differential Valve Assembly Parts List Recovery Tank Cover Assembly Parts List Vacuum Relief Valve Assembly Parts List Water Box Assembly Parts List Diffuser Filter Assembly Parts List Yaw Sensor Cooling Kit Parts List Pass Through Assembly Parts List Chevy Cowling Assembly Parts List Driver Side Pump Kit Assembly Parts List Passenger Side Pump Kit Assembly Parts List Pump Flex Assembly Parts List Gallon Tank Flex Kit Assembly Parts List Gallon Tank Flex Assembly Parts List Gallon and 15 Gallon Tank Kit Assembly Parts List Gallon and 15 Gallon Tank Flex Assembly Parts List Gallon Tank Solo Flex Assembly Parts List Gallon Tank Flex Assembly Parts List Gallon Tank Flex Chemical Caddy Assembly Parts List Gallon Tank Flex Chemical Caddy Assembly Parts List Quick Connect Dash Box Flex Assembly Parts List By-Pass Valve Flex Assembly Parts List Dura-Flow Automatic Pump Out (APO) Assembly Parts List APO Pump Parts List Pump Cover Flex Assembly Parts List Flex Install Kit Assembly Parts List Wire Harness Flex Assembly Parts List CDS Hose Routing List Flex Hose Routing List : Assemblies and Parts Lists

56 Some of the illustrations in this section reference sealants, thread lockers, adhesive, primer, anti-seize and lubricant specifications that are used in the construction of the CTS 4.8 Flex equipment. Refer to Figure 8-1 to identify those substances such as A1, A2 and so forth. Equivalent products are acceptable if they meet or exceed current specifications and are approved by HydraMaster. Assemblies and Parts Lists: 8-2 Figure 8-1. Adhesive and Sealant Material Reference

57 Figure 8-2. Top Level Assembly - View 1 of Rev. D If you want the CTS 4.8 Flex without the Flex Tank Assemblies and APO, order P/N : Assemblies and Parts Lists

58 Figure 8-3. Top Level Assembly - View 2 of Rev. D C B Assemblies and Parts Lists: 8-4

59 Figure 8-4. Top Level Assembly - View 3 of Rev. D Section B Section C Fastener Stackup for Power Pack Spacers Fastener Stackup for Tank Assemblies 8-5: Assemblies and Parts Lists

60 Figure 8-5. Top Level Assembly - View 4 of Rev. D Top Level Assembly Parts List Item Part Number Description Qty Assembly, Coolant Heat Exchanger Flex Assembly, Cover - Pump Flex Assembly, Cowling - Chevy CDS Gray Assembly, Dash Box - QC Flex Assembly, Dura-Flow APO Assembly, Power Pack Assembly, Pump - Passenger Flex Kit Assembly, Pump, Driver Flex Kit Assembly, Recovery Tank Flex Assembly, Salsa Heat Exchanger Flex Assembly, Tank - 35 Gallon and 15 Gallon Flex Kit Assembly, Tank - 50 Gallon Flex Kit Assembly, Front End Connector, 2 Plastic Vacuum Hose Drive Line Axle Finish Package, CDS Harness, Chevy - Secondary Harness, Wire - CTS 4.8 Flex Hose Assembly, 1/4 Solution X 125 Lg Hose, 2 X 50 Vacuum - Blue Hose, 3/4 Green Stripe X 18 Lg Kit, Installation Flex Kit, Mach Parts CDS Kit, Yaw Sensor Cooling - Chevy Label Set, Equipped D Manual, CTS 4.8 Flex Owners Guide (not shown) D Manual, CDS Owners Guide (not shown) Silencer, 3 Inlet and Outlet - Coated Spacer, Power Pack - Rear Spacer, Power Pack - Front 1 Assemblies and Parts Lists: 8-6

61 Figure 8-6. Recovery Tank Assembly - View 1 of Rev. C 8-7: Assemblies and Parts Lists

62 Figure 8-7. Recovery Tank Assembly - View 2 of Rev. C Assemblies and Parts Lists: 8-8

63 Figure 8-8. Recovery Tank Assembly - View 3 of Rev. C 8-9: Assemblies and Parts Lists

64 Figure 8-9. Recovery Tank Assembly - View 4 of Rev. C WATER BOX TO BY-PASS VALVE Assemblies and Parts Lists: 8-10

65 Recovery Tank Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Adapter, Ø3.0 Tank to X 90 Degree Blower Hose Assembly, Dash Box Assembly, Dual Heat Exchanger Assembly, Instrument Panel Assembly, Recovery Tank Cover Assembly, Vacuum Relief Valve - URT Assembly, Water Box Bracket, Flat Filter Securing - Uncoated Bracket, Instrument Panel to Vacuum Tank Stabilizer Clamp, 1-1/2 Cushion Loop Clamp, 1 Cushion Loop Clamp, Size #5 Hose Clamp, Size #16 Hose Elbow, 1/4 NPT Street Elbow, 1/4 NPT Street X 45 Degree Filter, Air Deflector, URT - Fabricated Filter, Chemical Inlet High Pressure Filter, Flat - URT Filter, Recovery Tank Basket Float, Lever Switch Gasket, 1/2 X 1/4 X 18-1/8 Lg Gasket, 1/2 X 1/8 X 100 ft Lg. Closed Cell Gasket, Adapter - URT Hinge, Dash Box Hose, 1/2 I.D. Rubber X 42 Lg Hose, 1/2 X 42.5 Lg w/ 3/8 NPT and 3/8 SAE F Ends Hose, 3/4 I.D. X 18 ft - Green Stripe - Cut to Fit Hose, 3/8 I.D. Rubber X 17 Lg Hose, 3/8 I.D. Rubber X 31 Lg Hose, 3/8 I.D. X 38 Lg., Clr w/braid Hose, 3/8 X 37 w/ 3/8 JIC End Hose, 3/16 X 34 1/4 FJIC X 1/4 FJIC Hose, 5/32 I.D. Vacuum X 52 Lg Hose, 5/32 I.D. Vacuum X 82 Lg Insert, 1-1/2 NPT X 1-1/2 Barb (Gray) Insert, #46 (1/4 NPT X 3/8 Barb) Label Set Latch, Bungee Latch, Dash Strike Nipple, 1-1/2 NPT X 4 Lg. S/S Nut, 1/4-20UNC Neoprene Wellnut Nut, 1/4-20UNC Nylock Nut, #6-32UNC Hex Nylock Nut, #10-24UNC Hex Nylock Plate, Machine Serial I.D Plug, 1-1/2 NPT Plug, 1-1/4 NPT Plug, 1 NPT Black Nylon Rivet, Ab4-3A Aluminum Pop 1/8 X 1/4 Lg Rivet, AB8-6A Aluminum Pop Screw, 1/4-20UNC X 0.50 Lg. Hex Head Screw, 1/4-20UNC X 1.00 Lg. Hex Head Screw, #6-32UNC X 0.50 Lg. Button Head Screw, #10-24UNC X Lg. Hex Head Screw, #10-24UNC X 0.50 Lg. Hex Head Tank, 100 Gallon Universal Recovery - Coated Tray, Soap Jug - Coated Trimlok, 3/8 X 1/8 Rubber Valve, 1-1/2 Full Port Ball Washer, 1/4 Flat Washer, 1/4 Flat Rubber Backed Washer, 1/4 Lock Washer, 3/8 Flat Rubber Backed Washer, #10 Flat Washer, #10 Flat Rubber Backed : Assemblies and Parts Lists

66 Figure Power Pack Assembly - View 1 of Rev. C Assemblies and Parts Lists: 8-12

67 Figure Power Pack Assembly - View 2 of Rev. C 8-13: Assemblies and Parts Lists

68 Power Pack Assembly Parts List Item Part Number Description Qty Assembly, Blower Assembly, Pump Assembly, Universal CDS Frame Belt, #9345 Pump Drive Belt, Polychain GT Bushing, #H X 7/8 Bore Clamp, 1-1/2 T-Bolt Clamp, Size #5 Hose Hose, 1 X 65 Lg. Suction Hose, 3/8 I.D. High Temp X 72 Lg Hose, 3/8 X 52 Lg. Throb - CDS Hose, 3/16 X 70 Lg. w/ Fem JIC Ends Hose,CDS Blower Oil Drain Nut, 1/4-20UNC Hex Nut, 5/16-18 UNC Hex 2 Item Part Number Description Qty Protector, Pump Belt Shield - Coated Protector, Pump Drive Belt - Coated Pulley, AK51H Screw, 1/4-20UNC X 1/2 Lg. Whiz Lock Screw, 3/8-16UNC X 1.00 Lg. Hex Head Screw, 3/8-16UNC X 1 Lg. Hex Head - Grade Screw, 3/8-16 X 2 1/2 Hex Head Screw, 5/16-18UNC X 1.00 Lg. Hex Head Grade Screw, 5/16-18UNC X 3/4 Lg Washer, 1/4 Flat Washer, 1/4 Flat Washer, 1/4 Lock Washer, 3/8 Lock Washer, 5/16 Flat, USS Washer, 5/16 Lock 8 Assemblies and Parts Lists: 8-14

69 Figure Blower Assembly Rev. B 8-15: Assemblies and Parts Lists

70 Blower Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Adapter, Blower Inlet - Coated Adapter, Blower Outlet - Coated Blower, Bracket, Blower Mounting - Coated Bracket, Tach. Magnetic Extension - Coated Bushing, 3/8 NPT X 1/4 FPT Bushing, 7/8 Taper-Lock Elbow, 1/4 NPT Street X 45 Degree Elbow, 1/8 NPT Street Hose, CDS Blower Oil Drain Hose, CDS Blower Oil Drain Insert, #23 (1/8 NPT X 3/16 Barb) Key, 3/16 X 1 1/2 Long Nipple, 1/8 NPT Hex Pulley, 2 3/4 X 7/8 Pump Drive - Machined Pulley, 40 Tooth Screw, 1/4-20UNC X 2 Lg. Hex Head Grade Screw, 1/4-20UNC X 3/4 Lg. Hex Head Screw, 3/8-16UNC X 1 Lg. Hex Head - Grade Screw, 3/8-16UNC X 3/4 Lg. Socket Head Sensor, CDS Magnetic Tach Spacer, Tach, Sensor Tee, 1/8 FPT Terminal,5/16 Ring-16 AWG Washer, 1/4 Flat Washer, 1/4 Lock Washer, 3/8 Lock Washer, 5/16 Flat 2 Assemblies and Parts Lists: 8-16

71 14 Figure Pump Assembly - View 1 of Rev. C 4 X X X 8MM LOCK WASHER 2 4X 8MM x 20MM LONG HEX BOLT 8-17: Assemblies and Parts Lists

72 Figure Pump Assembly - View 2 of Rev. C The pump service repair kit is P/N ; it includes the pump packing lubricant and the insertion tool. 4X 10MM X 14MM LONG HEX BOLT Assemblies and Parts Lists: 8-18

73 Pump Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Adapter, GP to Chemical Pump S/S 4.0 gallon Insert, #816 (1/2 NPT X 1 Barb) Bracket, Compressor Mount - Coated Nipple, 3/8 MPT X 3/8SAE Flare Bushing, 1/4 NPT Male X 1/4 NPT Female Nut, 1/4-20UNC Nylock Clutch, 7 O.D. 24mm Single Groove O-Ring, Adapter - Chemical Pump Elbow, 1/4 NPT Street Plate, Pump Clutch - GP 4.0 gpm Elbow, 1/8 NPT Street Pump, 4.0 gpm GP Elbow, 1/8 NPT X 1/4 SAE Pump, GP Chemical Elbow, 3/8 NPT Street Screw, 1/4-20UNC X 1/2 Lg. Whiz Lock Insert, #26 (1/8 NPT X 3/8 Barb) Valve, GP Pump Check - Mod gallon : Assemblies and Parts Lists

74 Figure Frame Assembly Rev. B X ZERK FITTING,1/8" MPT REFERENCE: Assemblies and Parts Lists:

75 Frame Assembly Parts List Item Part Number Description Qty Bearing, Pillow Block - 1-3/16 Bore Bushing, 1-1/8 Taper-Lock Clamp, 1 Cushion Loop Frame, Pump and Blower - Coated Key, 1/4 X 1-1/2 Lg. Class 2 Fit Key, 3/16 X 2.5 Lg. Class 2 Fit Nut, 1/2-13UNC 2 Way Locking Nut, 1/4-20UNC Hex Pulley, 56 Tooth GT2 8MX-56S-21 Engine and Blower Screw, #10-24UNC X 0.75 Lg. Hex Head 1 Item Part Number Description Qty Screw, 1/2-13UNC X 1.75 Lg. Hex Head - Grade Screw, 1/4-20UNC X 1.00 Lg. Hex Head Screw, 1/4-20UNC X 2.00 Lg. Hex Head Screw, 5/16-18UNC X 1.00 Lg. Hex Head Grade Shaft, Drive Sprocket Snap Ring, 1-3/16 Shaft Washer, #10 Flat Washer, #10 Lock Washer, 1/2 SAE H/D Washer, 5/16 Lock : Assemblies and Parts Lists

76 Figure Coolant Heat Exchanger Assembly Rev. C Assemblies and Parts Lists: 8-22

77 Coolant Heat Exchanger Assembly Parts List Item Part Number Description Qty Assembly, Cross Flex Kit Bracket, After Burner Mounting Saddle - Fabricated Bracket, Coolant Heat Exchanger - Uncoated Clamp, 1 Cushion Loop Clamp, After Burner Mount Lg Elbow, 3/4 NPT X 3/4 Barb Fitting, 3/4 NPT Street Elbow - Modified Heat Exchanger, Coolant - Weldment Hose Assembly, 3/4 I.D. Green Stripe X 18 Lg Insert, #1212 Brass Nipple, 3/8 NPT X 9/ Degree JIC S/S 2 Item Part Number Description Qty Nut, 1/4-20UNC Nylock Nut, 5/16-18UNC Nylock Protector, Coolant Heat Exchanger Protector, Heat Exchanger Pad Ø Rod, Heat Exchanger Strap Retainer - Fabricated Screw, 1/4-20UNC X 0.75 Lg. Hex Head Screw, 5/16-18UNC X 2.00 Lg. Hex Head Valve, Petcock 90 Degree Washer, 1/4 Flat Washer, 5/16 Flat : Assemblies and Parts Lists

78 Figure Blower Heat Exchanger Assembly Rev. A * Check anodes every 500 hours and replace as necessary. Assemblies and Parts Lists: 8-24

79 Blower Heat Exchanger Assembly Parts List Item Part Number Description Qty Core, S/S Heat Exchanger 6 X 8 (8 Row) Elbow, 3.00 O.D. X Wall Elbow, 3 Rubber w/clamps Elbow, 3/8 S/S Street Hose, 5/16 X 68 Lg. - Blower Heat Exchanger to Coolant Heat Exchanger Nipple, 3/8 NPT X 9/ Degree JIC S/S Nut, #8-32UNC Nylock Panel, Blower Inlet - Weldment 1 Item Part Number Description Qty Panel, Blower Outlet - Weldment Plug, 3/8 NPT Allen Head Plug, Pipe, 1/4, Flush Fitting Protector, Magnesium Anode * Protector, Blower Insulation Set Rivet, 1/4 Blind X 0.50 Lg Spring, Solution Valve Washer, #10 Flat 4 * Check anodes every 500 hours and replace as necessary. 8-25: Assemblies and Parts Lists

80 Figure Cross Kit Assembly Rev. B Cross Kit Assembly Parts List Item Part Number Description Qty Elbow,3/8 S/S Female Nipple, 3/8 NPT X 9/ Degree JIC S/S Insert, #64 (3/8 NPT X 1/4 Barb) S/S Cross, 3/8 FPT S/S Valve, 3/8 Hi-PSI S/S - Check Hose Assembly, 5/16 I.D. X 35 Lg. - Coolant Heat Exchanger to Hi-PSI 1 Assemblies and Parts Lists: 8-26

81 Figure Dash Box Assembly Rev. D 8-27: Assemblies and Parts Lists

82 Dash Box Assembly Parts List Item Part Number Description Qty Assembly, Dash Panel Box, Dash - Coated Bracket, Grounding Bus - Fabricated Fuse Holder, In-Line - Weatherproof Fuse, 15 Amp Plug In Grommet, Large Wiring Latch, Dash Securing Plate, Dash Name - Coated Reflector, X 11 1 Item Part Number Description Qty Screw, #6-32 X.500 Lg. PHP Screw, #10-24UNC X Lg. Hex Head Screw, #10-24UNC X 0.50 Lg. Flat Head Phillips Screw, #10-24UNC X 0.50 Lg. Hex Head Shield, Drip - Dash Switch, Relay Trimlok, 1/8 I.D. X 3/8 9 ft Washer, #6 Lock Washer, #10 Outside Star 3 Assemblies and Parts Lists: 8-28

83 Figure Dash Panel Assembly Rev. C 8-29: Assemblies and Parts Lists

84 Dash Panel Assembly Parts List Item Part Number Description Qty Breaker, 25 Amp Circuit Elbow, 1/8 NPT Street Gauge, Tach. Mag Pick Up 3-3/8 Dia Gauge, Temperature Gauge, Vacuum Insert, #F23 (1/8 FPT X 3/16 Barb) Lamp, Replacement Gauge Lamp, Socket - Dashboard 3 Item Part Number Description Qty Light, Red LED Indicator Mini Meter, Rectangular w/o Bezel Panel, Dash - Coated Switch, Pump Selection/CDS Speed Control Switch, 20 Amp Rocker Switch, Ignition Washer, 3/8 Flat 1 Assemblies and Parts Lists: 8-30

85 Figure Dual Heat Exchanger Assembly Rev. M 8-31: Assemblies and Parts Lists

86 Dual Heat Exchanger Assembly Parts List Item Part Number Description Qty Bracket, Heat Exchanger Mounting - Coated Bushing, 1/2 M X 3/8 F Clamp, Size #4 Mini Hose Clamp, Size #12 Hose Elbow, 3/8 NPT Street Elbow, 3/4 NPT Street Fitting, 3/4 NPT Street Elbow - Modified Heat Exchanger, Water to Water Hi-PSI Hose, 3/8 X 12 Lg. w/ JIC Ends Hose, 3/4 I.D.w/ 180~ Bend for Heat Exchanger Hose, 3/8 I.D. Clear - Bulk Hose, 3/8 I.D. X 11 Lg w/ 3/8 MPT and 3/8 JIC End Insert, #1212 Brass Insulation, 4-1/8 X 1/ Nipple, 3/8 M JIC X 3/8 NPT Nut, 1/4-20UNC Hex Nut, 1/4-20UNC Neoprene Wellnut Screw, 1/4-20UNC X 1.00 Lg. Hex Head Valve, Petcock 90 Degree Washer, 1/4 Rubber Backed Washer, 1/4 Lock Washer, 1/4 Flat Washer, 1/4 Flat 4 Figure CDS Heat Exchanger Core Assembly - Product Support Rev. B Order two P/N when replacing original P/N and P/N * Use P/N for Product Support (see Figure 8-22). Assemblies and Parts Lists: 8-32

87 Figure Instrument Panel Assembly - View 1 of Rev. G 8-33: Assemblies and Parts Lists

88 Figure Instrument Panel Assembly - View 2 of Rev. G Apply hydraulic sealant to all pipe threads. All these items - 3, 12, 22, 30, 48 and 50 - replace item 35 when the APO, P/N , is installed. Items 24 and 25 are part of label set P/N Assemblies and Parts Lists: 8-34

89 Item Part Number Description Qty Instrument Panel Assembly Parts List Item Part Number Description Qty Assembly, By-Pass Valve Assembly, Hi-PSI Manifold Cap, Garden Hose Clamp, 3/4 Nylon Hose Clamp, Size #5 Hose Cup, Gravity Feed Oil Blower Lube Port Elbow, 1/8 NPT Female Elbow, 1/8 NPT Street Elbow, 1/8 NPT X 1/4 SAE Elbow, 1/4 FPT X FPT Elbow, 3/4 NPT X 3/4 Barb Gasket, Garden Hose Gauge, Pressure 0-1,500 psi Grommet, Large Wiring Hose, 1/2 X 20.5 Lg. Rubber w/ 3/8 NPT X 3/8 S Hose, 3/8 Bulk Hose, 3/8 Bulk Hose, 3/16 X 10 Lg. 1/4 NPT X 1/4 JIC F Hose, 3/16 X Lg. w/f JIC Ends Insert, #26 (1/8 NPT X 3/8 Barb) Insert, #66 (3/8 NPT X 3/8 Barb) Insert, #1212 (3/4 NPT X 3/4 Barb) Insert, #F23 (1/8 FPT X 3/16 Barb) Label, Lower Instrument Panel Label, Upper Instrument Panel Meter, Chemical Flow Raw Nipple, 1/8 NPT Hex Nipple, 1/4 SAE X 1/8 NPT Nipple, 3/8 MPT X 3/8 SAE Flare Nipple, 3/4 NPT X 3/4 Male Garden Hose Nut, 7/16-24UNF - 2 Way Metering Valve Nut, #10-24UNC Hex Panel, Instrument - Coated Plate, Machine Serial I.D Plug, 1 Hole Quick Connect, 440 Female w/ EPDM O-Ring Quick Connect, 660 3/8 Brass w/ EPDM O-Ring Regulator, Hi-PSI Snubber Rivet, 1/8 X 1/4 Lg. Pop Screw, #10-24UNC X Lg. Hex Head Screw, #10-32UNF X 0.50 Lg. Hex Head Screw, #10-24UNC X 1 Lg. Hex Head S/S Tee, 3/8 Insert Trimlok, 1/8 X 3/16 Lg Valve, 3-Way Ball O-Ring Style Valve, 3/4 Heater Panel Mount Valve, 3/8 NPT Full Port Ball Valve, 3/4 FPT Swing Check Valve, Chemical Metering Washer, 1 Flat Washer, 1/2 SAE H/D Washer, 1/2 Flat Washer, 1.5 O.D. X I.D. X Thk Washer, 3/8 Flat Washer, 5/8 Flat Washer, 5/8 I.D. X 7/8 O.D. X Thk Washer, #10 Flat Washer, #10 Lock Washer, #10 Outside Star : Assemblies and Parts Lists

90 Figure By-Pass Valve Assembly Rev. C BOTTOM VIEW See Figure 8-1 for adhesive/sealant information. Assemblies and Parts Lists: 8-36

91 By-Pass Valve Assembly Parts List Item Part Number Description Qty Bracket, By-Pass Valve Mount - Weldment Cap, 3/8 Brass Pipe Elbow, 1/4 SAE X 3/8 MPT X 90 Degrees Insert, #26 (1/8 NPT X 3/8 Barb) Insert, #68 (3/8 NPT X 1/2 Barb) Nipple, 3/8 M JIC X 3/8 NPT Nipple, 3/8 MPT X 3/8 SAE Flare 1 Item Part Number Description Qty Plug, 3/8 NPT Allen Head Screw, #10-24UNC X 0.50 Lg. Hex Head Tee, 3/8 NPT Male Street Valve, 165 Degrees F Thermal Valve, Pressure Regulator-Modified * Washer, #10 Flat Washer, #10 Lock 2 The By-Pass Valve Assembly for the Instrument Panel Assembly is P/N (see Figure 8-25). * Order P/N for the valve repair kit. The By-Pass Valve Assembly for the Flex s Quick Connect Box is P/N (see Figure 8-48). 8-37: Assemblies and Parts Lists

92 Figure Hi-PSI Manifold Assembly Rev. E Hi-PSI Manifold Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Bushing, 3/8 NPT X 1/4 FPT Nipple, 3/8 M JIC X 3/8 NPT Bushing, 3/8 NPT X 1/8 FPT Nipple, 3/8 NPT Hex Cross, 3/8 FPT Nipple, Tee Jet Style Collar X 1/8 NPT Elbow, 1/8 NPT X 1/4 SAE Nut, Brass Jet Assembly Filter Cartridge,1/4 Brass Orifice, Plate Housing, Stabilizer Nozzle Plug, 1/4 NPT Hex Manifold, High Pressure Sender, Temperature Nipple, 1/4 NPT Hex Valve, Differential Nipple, 1/8 FPT X 1/4 SAE 1 Assemblies and Parts Lists: 8-38

93 Figure Differential Valve Assembly Rev. B Differential Valve Assembly Parts List Item Part Number Description Qty Ball, dia S/S Body, Differential Check Valve Cap, Differential Check Valve O-Ring, Check Valve Plug O-Ring, Chemical Pump Valve Seat, Differential Check Valve Spring, Differential Check Valve 1 : Apply O-ring grease or equivalent to items 5 and 4 prior to installation. 8-39: Assemblies and Parts Lists

94 3 Figure Recovery Tank Cover Assembly Rev. B Recovery Tank Cover Assembly Parts List 5 Item Part Number Description Qty Item Part Number Description Qty Adapter, 2 NPT X 2 F Slip Gasket, Side - URT Cover Cover, 100 Gallon Universal Recovery Tank - Coated Latch, Bungee - Strike (Part of ) Elbow, 2 Barb X 2 FPT Nut, #6-32UNC Nylock Gasket, 1-1/2 Bulkhead Fitting Screw, #6-32UNC X 0.50 Lg. Button Head Gasket, End - URT Cover Vacuum Inlet Stopper Gasket, Middle - URT Cover 3 Assemblies and Parts Lists: 8-40

95 Figure Vacuum Relief Valve Assembly Rev. B Vacuum Relief Valve Assembly Parts List Item Part Number Description Qty Bracket, Vacuum Relief Valve - Fabricated Cap, Spun Vacuum Relief Valve Nut, 3/8-16UNC Hex Jam Nut, 3/8-16UNC X 1.00 O.D. Knurled 2 Item Part Number Description Qty Plate, Vacuum Relief Valve Mounting - Coated Screw, 3/8-16UNC X 4 Lg.HH Spring, Vacuum Relief Valve Tube, Vacuum Relief Spring Guide : Assemblies and Parts Lists

96 Figure Water Box Assembly - View 1 of Rev. A Assemblies and Parts Lists: 8-42

97 Figure Water Box Assembly - View 2 of Rev. A 8-43: Assemblies and Parts Lists

98 Water Box Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Assembly, Diffuser Filter Nut, 1/4-20UNC Neoprene Wellnut Assembly, Float Valve O-Ring, 1/2 Bulk Head Bracket, Water Box Mounting - Coated Screw, #8 X 1/2 Lg. Pan Head Bulkhead, 1/2 FPT Screw, 1/4-20UNC X 1.00 Lg. Hex Head Bulkhead, 3/8 FPT X 3/8 FPT Screw, 3/8-16UNC X 0.75 Lg. Hex Head Grd Clamp, Size #5 Hose Switch, w/protector, Polypropylene Barrel Cover, 6 Access Tank, Poly Water Box Elbow, 3/8 NPT Street Tee, 3/16 Plastic Vacuum Insert Elbow, 3/8 NPT X 1/2 Hose, GFBN Tee, 3/8 NPT Male Street Hose, 3/8 I.D. Clear w/ Braid Solution Washer, 1.5 O.D. X I.D. X Thk Insert, #66 (3/8 NPT X 3/8 Barb) Washer, 1/4 Lock Insert, #F816 (1/2 FPT X 1 Barb) Washer, 1/4 Rubber Backed Nipple, 3/8 NPT X 1/4 M SAE Washer, 3/8 Flat Nut, 1-14UNS Brass Washer, 3/8 Lock 4 Assemblies and Parts Lists: 8-44

99 Figure Diffuser Filter Assembly Rev. B Diffuser Filter Assembly Parts List Item Part Number Description Qty Cap, 2 PVC Modified for Diffuser Clamp, Diffuser Insert, #66 (3/8 NPT X 3/8 Barb) 1 Item Part Number Description Qty Nipple, 3/8 NPT Hex Tube, Diffuser : Assemblies and Parts Lists

100 Figure Yaw Sensor Cooling Kit Assembly Rev. A Yaw Sensor Cooling Kit Parts List Item Part Number Description Qty Clamp, 1-1/2 Cushion Loop Clamp, Size #12 Hose Filter Screen - Medium Fitting, Yaw Sensor Cooling Hose, 1 Vacuum - Gray W Hose, 1 Vacuum - Gray W Insert 3/4 X 1 Hose w/o Barb Screw,10-24 X 1/2 Self Tapping Pan HD-Phillips Weldment, Yaw Sensor Cooling - Chevy 1 Assemblies and Parts Lists: 8-46

101 Figure Pass Though Assembly Rev. C Pass Through Assembly Parts List Item Part Number Description Qty Cable, 150 lb Test S/S Clamp, Throttle Cable Cover, 4 Round ABS-Mod. - Pass Through Screw, #10 X 1.5 Lg. Pan Head Sheet Metal Tube, Pass Through : Assemblies and Parts Lists

102 Figure Chevy Cowling Assembly Rev. A Chevy Cowling Assembly Parts List Item Part Number Description Qty Cowling, Chevy Label, Driveline Lubrication Procedure and Specification Trimlok, 3/4 Bulb 1 ft Figure 8-35 shows cowling before being modified during final installation. Assemblies and Parts Lists: 8-48

103 Figure Driver Side Pump Kit Assembly Rev. B Driver Side Pump Kit Assembly Parts List Item Part Number Description Qty Assembly, Pump Clamp, Size #4 Mini Hose Hose, 1/4 I.D. Rubber X 110 Lg. - Pump to Cross Nut, #10-24UNC Nylock Plate, Pump Mounting Screw, #10-24UNC X 1.25 Lg. Hex Head Washer, #10 Flat : Assemblies and Parts Lists

104 Figure Passenger Pump Kit Assembly Rev. C Passenger Side Pump Kit Assembly Parts List Item Part Number Description Qty Assembly, Pump Clamp, Size #4 Mini Hose Hose, 1/4 I.D. Rubber X 173 Lg. - Pump to Cross Nut, #10-24UNC Nylock Plate, Pump Mounting Screw, #10-24UNC X 1.25 Lg. Hex Head Washer, #10 Flat 8 Assemblies and Parts Lists: 8-50

105 Figure Pump Flex Assembly Rev. B Pump Flex Assembly Parts List Item Part Number Description Qty Strainer Clamp, Size #6 Mini Hose Connector, 2 Pole Water Tight Female Elbow,3/8 S/S Street Elbow, 3/8 NPT X 1/2 Hose, GFBN Hose, 1/2 I.D. PVC X 8 Lg. - Braided - Pump to Strainer Insert, #64 (3/8 NPT X 1/4 Barb) S/S Pin, Female Pump Seal, Water Tite Wire Connector Wire, 1/4 Loom 1.5 ft 8-51: Assemblies and Parts Lists

106 Figure Gallon Tank Flex Kit Assembly Rev. C 50 Gallon Tank Flex Kit Assembly Parts List Item Part Number Description Qty Assembly, Chemical Caddy 50 Gallon Assembly, Tank 50 Gallon Frame, 12 X 60 Tank - Coated Protector, Bulkhead 1 Assemblies and Parts Lists: 8-52

107 Figure Gallon Tank Flex Assembly Rev. E The following items are shipped with the Tank Assembly in a plastic bag, ready to be used at installation: Item 2, 1X; Item 3 1X; Item 6; Item 9; Item Gallon Tank Flex Assembly Parts List Item Part Number Description Qty Bulkhead Clamp, 1 Cushion Loop Clamp, Size #6 Mini Hose Cover, 6 Access Elbow, 1/2 NPT X 1/2 Hose Elbow, 3/8 NPT X 1/2 Hose Hose, 1/2 I.D. Clr X 16 Lg. Braid - 3 Way Valve to Pump Filter Hose, 1/2 I.D. Clr X 54 Braid Hose, 1/2 I.D. Clr X 78 Lg. Braid - Vent Magnet Miniature 3 Way PVC Ball Valve Nut, #10-24UNC Nylock Plate, Tank Cover Plug, 3/8 NPT Allen Head Screw, #8 X 1/2 Lg. Pan Head Screw, #10-24UNC X 0.50 Lg. Hex Head Tank, 50 Gallon - Modified : Assemblies and Parts Lists

108 Figure Gallon and 15 Gallon Tank Kit Assembly Rev. C 35 Gallon and 15 Gallon Tank Kit Assembly Parts List Item Part Number Description Qty Assembly, Chemical Caddy 35 Gallon Assembly, Tank - 35 Gallon and 15 Gallon Frame, 12 X 53 Tank - Coated Protector, Bulkhead 2 Assemblies and Parts Lists: 8-54

109 Figure Gallon and 15 Gallon Tank Flex Assembly Rev. E 8-55: Assemblies and Parts Lists

110 35 Gallon and 15 Gallon Tank Flex Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Bulkhead Clamp, 1 Cushion Loop Clamp, Size #6 Mini Hose Cover, 6 Access Elbow, 1/2 NPT X 1/2 Hose Elbow, 3/8 NPT X 1/2 Hose Hose, 1/2 I.D. Clr X 16 Lg. - Braid Hose, 1/2 I.D. Clr X 36 Lg. - Braid Hose, 1/2 I.D. Clr X 54 Lg. Braid - Drain Hose Hose, 1/2 I.D. Clr X 78 Lg. Braid - Vent Hose Magnet Miniature 3 Way PVC Ball Valve Nut, #10-24UNC Nylock Plate, Tank Cover Plug, 3/8 NPT Allen Head Screw, #8 X 1/2 Lg. Pan Head Screw, #10-24UNC X 0.50 Lg. Hex Head Tank, 15 Gallon - Modified Tank, 35 Gallon - Modified 1 The following items are shipped with the Tank Assembly in a plastic bag, ready to be used at installation: Item 2, 2X; Item 3, 2X; Item 6, 2X ; Item 10, 2X; Item 15, 2X Assemblies and Parts Lists: 8-56

111 Figure Gallon Tank Solo Flex Assembly Rev. C 35 Gallon Tank Solo Flex Assembly Parts List Item Part Number Description Qty Assembly, Chemical Caddy 35 Gal Assembly, Tank, 35 Gallon Solo Frame, X Tank - Coated Protector, Bulkhead : Assemblies and Parts Lists

112 Figure Gallon Tank Flex Assembly Rev. C 35 Gallon Tank Flex Assembly Parts List Item Part Number Description Qty Bulkhead Clamp, 1 Cushion Loop Clamp, Size #6 Mini Hose Cover, 6 Access Elbow, 1/2 NPT X 1/2 Hose Elbow, 3/8 NPT X 1/2 Hose Hose, 1/2 I.D. Clear X 16 Lg. - 3 Way Valve to Filter Hose, 1/2 I.D. Clear X 32 Lg. - Braid Hose, 1/2 I.D. Clear X 54 Lg. - Braid - Drain Hose Hose, 1/2 I.D. Clear X 78 Lg. Braid - Vent Hose Magnet, Miniature 3 Way PVC Ball Valve Nut, #10-24UNC Hex Nylock Plate, Tank Cover Plug, 3/8 NPT Allen Head Screw, #8 X 1/2 Lg. Pan Head Screw, #10-24UNC X 0.50 Lg. Hex Head Tank, 35 Gallon - Modified 1 Assemblies and Parts Lists: 8-58

113 Figure Gallon Tank Flex Chemical Caddy Assembly Rev. B 50 Gallon Tank Flex Chemical Caddy Assembly Parts List Item Part Number Description Qty Bracket, Tank Stiffener Bracket, Tank Tray Rib X 3 12X Nut, 1/4-20UNC Nylock Half 12 6X Screw, 1/4-20UNC X 0.50 Lg. Hex Head Tray, Tank Washer, 1/4 Flat 12 3X X 8-59: Assemblies and Parts Lists

114 Figure Gallon Tank Flex Chemical Caddy Assembly Rev. B 35 Gallon Tank Flex Chemical Caddy Assembly Parts List Item Part Number Description Qty Bracket, Tank Stiffener Bracket, Tank Tray Rib Nut, 1/4-20UNC Nylock Half Screw, 1/4-20UNC X 0.50 Lg. Hex Head Tray, Tank Washer, 1/4 Flat 12 Assemblies and Parts Lists: 8-60

115 Figure Quick Connect Dash Box Assembly Rev. B 8-61: Assemblies and Parts Lists

116 Item Part Number Description Qty Quick Connect Dash Box Flex Assembly Parts List Item Part Number Description Qty Nut, #10-24UNC Wing S/S Assembly, By-Pass Valve * Elbow,1/4 Street S/S Filter, In-Line Quick Connect Grommet, 1.00 I.D. X 1.50 O.D Hose Assembly, 5/16 X 59 Lg. - Hose Clean Out Nipple, 1/4 MPT X 9/ Nipple, 1/4 S/S Hex Orifice, Set Screw #10-32UNF X I.D Panel, QC- Front and Bottom Panel, QC - Left and Top Panel, QC - Right Quick Connect, 1/4 Female S/S Quick Connect, 440 Male w/ Viton Std Screw, #10-24UNC X 0.50 Lg. Hex Head Tee, 1/4 Female S/S Washer, 1/2 Flat Washer, #10 Flat 9 *The By-Pass Valve Assembly for the Instrument Panel Assembly is P/N (see Figure 8-25). The By-Pass Valve Assembly for the Flex s Quick Connect Dash Box is P/N (Figure 8-48). Assemblies and Parts Lists: 8-62

117 Figure By-Pass Valve Flex Assembly Rev. B By-Pass Valve Flex Assembly Parts List Item Part Number Description Qty Bracket, By-Pass Valve Mount - Weldment Clamp, Size #6 Mini Hose Elbow, 3/8 NPT X 1/2 Hose Elbow,3/8 S/S Female Hose Assembly, 5/16 X 21 Lg. - Hose By-Pass to Orifice Manifold Hose Assembly, 5/16 X 82 Lg. - Hose By-Pass In-Let - Hi-PSI Hose Hose, 1/2 Rubber X 60 Lg Nipple, 3/8 NPT X 9/ Degrees JIC S/S Valve, S/S Press Reg 1 The By-Pass Valve Assembly for the Instrument Panel Assembly is P/N (see Figure 8-25). The By-Pass Valve Assembly for the Flex s Quick Connect Box is P/N (see Figure 8-48). 8-63: Assemblies and Parts Lists

118 Figure Dura-Flow Automatic Pump Out (APO) Rev. F See Figure 8-1 for adhesive/sealant information. Assemblies and Parts Lists: 8-64

119 Dura-Flow Automatic Pump Out (APO) Assembly Parts List Item Part Number Description Qty Item Part Number Description Qty Assembly, APO Pump Insert, #1212 (3/4 NPT X 3/4 Barb) Bracket, Dura-Flow Support - Fabricated Motor, Leeson PE350 Series Cap, Garden Hose Nipple, 3/4 NPT X 3/4 Male Garden Hose Clamp, Size #12 Hose Screw, 1/4-20UNC X 0.50 Lg. Hex Head Self-Tapping Clamp, Size #16 Hose Screw, 1/4-20UNC X 0.75 Lg. Hex Head Connector, Butt 10/ Screw, 1/4-28UNF X 0.75 Lg. Socket Head Connector, Butt 14/16 Blue Switch, Harwil Float - Modified Elbow, 1 NPT X 1 Barb (Glass Filled Black Nylon) Terminal, 3/8 Stud 10 GA Wire w/ Vinyl Fuse Holder, In-Line - Weatherproof Terminal, 10 AWG Fully Insulated Female Fuse, 25 Amp Terminal, 10 AWG Fully Insulated Male Gasket, Garden Hose Tie Wrap, 4 Nylon Harness, 1/4 Split Wire Loom 2 ft Valve, 3/4 FPT Swing Check Hose, 1 I.D. Rubber X 16 Lg. - Red Washer, 1 Flat Hose, 3/4 I.D. EPDM X 36 Lg Washer, 1/4 Lock Insert, 1 NPT X 1 Barb Washer, 1/4 Flat Insert, 1 NPT X 3/4 Elbow Washer, 1.5 O.D. X I.D. X Thk : Assemblies and Parts Lists

120 Figure APO Pump Rev. D APO Pump Parts List Assemblies and Parts Lists: 8-66 Item Part Number Description Qty Mount, APO Pumphead - Coated Plate S/S APO Inner Wear Plate S/S APO Outer Wear Pump 1

121 Figure Pump Cover Flex Assembly Rev. B Pump Cover Flex Assembly Parts List Item Part Number Description Qty Cover, Pump Magnet Nut, #10-24UNC Nylock Screw, #10-24UNC X Lg. Button Head Socket Trimlok, 1/8 X 3/8 2 ft 8-67: Assemblies and Parts Lists

122 Figure Flex Install Kit Assembly Rev. B Flex Install Kit Assembly Parts List 20X 10X 10X 2 Item Part Number Description Qty /16 Allen L-Key /8-16 X 2 Tap Bolt Nut, 3/8-16UNC Hex 2-Way Locking Screw, #8 Washer Head X 1/2, Philips - Self Drill Tie Down Cleat Washer - Fabricated Washer, 3/8 Flat 20 16X 5 8X 4 1 Assemblies and Parts Lists: 8-68

123 Figure Wire Harness Flex Assembly Rev. A Items 7 and 9 (not shown in Figure 8-53) to be installed on Item 1. (PLUS) (PLUS) (MINUS) (MINUS) Wire Harness Flex Assembly Parts List Item Part Number Description Qty Connector, 2 Pole Water Tight Female Wire Harness Wrap - Bulk Split Seam 2 ft Wire Harness Wrap - Bulk Split Seam 4 ft Wire Harness Wrap - Bulk Split Seam 6 ft Harness Wrap, 3/4 Split 16 ft Wire Harness Wrap - Bulk Split Seam 10 ft Seal, Water Tite Wire Connector 4 Item Part Number Description Qty Terminal, 3/8 Stud, 10 GA Wire, Insulated Terminal, Male Pin Polewater Tight Terminal, Fully Insulated Female, ga Wire, 12 GXL Red - Bulk Wire, 12 GXL Red - Bulk 31 ft Wire, 12 GXL White - Bulk 22 ft Wire, 12 GXL White - Bulk 28 ft 8-69: Assemblies and Parts Lists

124 CDS Hose Routing List Part Number Description From To Hose, 3/8 X 15 w/ 3/8 JIC End Dual Heat Exchanger CDS: By-Pass Valve Hose, 3/8 I.D. X 38 Lg., Clr w/braid Chemical Jug Chemical Meter Hose, 3/8 I.D. Rubber X 31 Lg. CDS: By-Pass Valve Recovery Tank Hose, 3/8 I.D. X 11 Lg w/ 3/8 MPT and 3/8 JIC End CDS: By-Pass Valve Dual Heat Exchanger Hose, 3/16 X 34 1/4 F JIC X 1/4 F JIC Water Box Hi-PSI Manifold Hose, 3/4 I.D. X 18 ft - Green Stripe - Cut to Fit Dual Heat Exchanger Van Cooling System Hose, 1/2 X 42 1/8 Lg w/ 3/8 NPT and 3/8 SAE F Ends Water Box Water Outlet Hose, 3/8 I.D. Rubber X 17 Lg. Hi-PSI Manifold Dual Heat Exchanger Hose, 5/32 I.D. Vacuum X 52 Lg. Pressure Gauge Blower Outlet Hose, 5/32 I.D. Vacuum X 52 Lg. Lube Port Blower Hose, 1/2 I.D. Rubber X 42 Lg. Water Box CDS: By-Pass Valve Assemblies and Parts Lists: 8-70

125 Flex Hose Routing List Part Number Qty Description From To /2" Clear x 8" Lg Pump Filter Pump Inlet /16" Hi-PSI x 21" Lg QC Box: By-Pass Valve QC Box: Orifice and Filter Manifold /16" Hi-PSI x 68" Lg Coolant Heat Exchanger Blower Heat Exchanger /16" Hi-PSI x 59" Lg Cross QC Box: Clean Out Port /16" Hi-PSI x 35" Lg Cross Coolant Heat Exchanger /2" Clear x 16" Lg Tank Select Valve Primary Valve /2" Clear x 16" Lg Primary Valve Pump Filter /2" Clear x 32" Lg 35 Gallon Tank Tank Select Valve /2" Clear x 36" Lg 15 Gallon Tank Tank Select Valve /2" Clear x 54" Lg Primary Valve Drain /2" Clear x 54" Lg 50 Gallon Tank Primary Valve /2" Clear x 78" Lg Tank Vent /4" Rubber x 110" Lg Driver's Side Pump Cross /4" Rubber x 173" Lg Passenger's Side Pump Cross /16" Hi-PSI x 82" Lg Blower Heat Exchanger QC Box: By-Pass Valve /2" Rubber x 60" Lg QC Box: By-Pass Valve Drain 8-71: Assemblies and Parts Lists

126 Assemblies and Parts Lists: 8-72

127 9 - Machine Maintenance To avoid costly repairs and down-time, it is imperative to develop and practice good maintenance procedures from the beginning. These procedures fall into daily, weekly, monthly and quarterly increments, and are outlined in this section. All recommended maintenance must be performed by competent service personnel. This section covers: Operational Maintenance Appearance Maintenance Van Long-Term Maintenance Schedule Drive Shaft Maintenance Troubleshooting Descaling Flex System as Required Back Flushing Heat Exchangers Clean QC Dash Box Filters and Orifices Pump Tuning Instructions Record the date and machine hours on the maintenance log provided for your convenience in the Owner s Guide. Records of maintenance must be kept and copies may be required to be furnished to HydraMaster before the warranty is honored. It is recommended that you affix a copy of the log on the vehicle door near your unit for convenience and to serve as a maintenance reminder. OPERATIONAL MAINTENANCE This section contains recommendations for maintenance that will affect the service life of your unit. HydraMaster recommends that you follow the vehicle maintenance schedule as stated by the manufacturer. All HydraMaster references to vehicle maintenance serve as general vehicle service reminders. If there are any questions regarding servicing of your vehicle, please contact your local vehicle dealership. 9-1: Machine Maintenance

128 Daily Check engine oil level. Empty recovery tank inlet filter. Check Flex strainers (filter screens and plastic housings) for debris; clean as necessary. Inspect and clean garden hose screen. Visually inspect machine for loose wires, oil leaks, water leaks, etc. Inspect recovery tank stainless steel filter for clogging or damage; clean, repair or replace as needed. Inspect and clean the vacuum slot on the cleaning wand. Watch for sharp edges that may tear the carpet; remove any sharp edges as required. Lubricate blower with a HydraMaster-recommended spray lubricant (P/N ) through blower lube port. Park the vehicle inside or turn on heater during freezing weather. Weekly Check around vehicle and CDS unit for any evidence of oil/fluid leaks. Grease, oil, antifreeze, and debris build-up near hot equipment, such as the vehicle engine exhaust system or the blower exhaust system, can present a fire hazard and can cause death or bodily injury. Vehicle engine exhaust system or the blower exhaust system, can present a fire hazard and can cause death or bodily injury. Clean and inspect float switches. Change pump oil after first 50 hours; every 300 hours thereafter. Check pump oil. Add as necessary. Check pump drive belt for wear. Check pump pulleys for wear. Check blower mounting fasteners, drive shaft clamping collar fasteners, and front end component fasteners, tighten as needed. Check internal machine high pressure water lines for wear or chafing. Clean and inspect recovery tank inlet filter. Machine Maintenance: 9-2

129 Inspect and clean vacuum relief valve. Inspect all external solution hoses, vacuum hoses, and quick connects for wear or damage that may cause premature failure, replace as needed. Clean recovery tank thoroughly with high pressure washer. Check vehicle engine rpm on tachometer: Speed 1 = 1,500 Speed 2 = 1,400 Speed 3 = 1,300 Monthly Check engine air cleaner filter. Clean as necessary. Clean Flex strainers (filter screens and plastic housings) with water. Clean and inspect the QC Dash Box in-line quick connect filters and orifices every 100 hours (see page 9-14). Check blower drive belt. Clean and inspect battery connections as needed. Change blower oil after first 100 hours. Every 2 Months (60 Days) Tune Flex System pumps. See page 9-15 of this Owner s Manual for pump tuning instructions. Quarterly Change oil in blower every 400 hours. Change oil in pump every 300 hours. Replace pump drive belt (P/N ) every 300 hours. Check the CDS wiring harness for any chafing or wear, especially in the vehicle engine compartment or near any rotating parts. Check the vehicle wiring harness for any chafing or wear, especially in the vehicle engine compartment or near any rotating parts. Grease the power pack pillow block bearings. 9-3: Machine Maintenance

130 Every 500 Hours Grease drive shaft U-joints, spline and zerks. Clean and inspect blower heat exchanger. Check blower heat exchanger magnesium anodes (P/N ) and replace as necessary. Back flush all heat exchangers. Yearly Give van complete vehicle service. Flush the van s cooling system. Add new anti-freeze. Change the van s transmission fluid. Change engine oil and filter after every 2,000 miles. Refer to the Interval Hours Maintenance chart in the Owner s Guide. Machine Maintenance: 9-4

131 APPEARANCE MAINTENANCE Maintaining the original appearance of your unit is important for two reasons: 1. It represents a big dollar investment for your cleaning business and its appearance should reflect that fact. A dirty machine does not look professional. 2. Maintenance, troubleshooting and repair is much easier to accomplish on a clean, well-maintained unit. Regular cleaning of the machine offers you an opportunity to visually inspect all parts of the machine and spot potential problems before they occur. The following maintenance is recommended by the manufacturer at the frequency indicated: Daily Wipe machine down thoroughly with a damp cloth. Flush recovery tank out thoroughly. Clean wand to maintain original appearance. Wipe down vacuum and high pressure hoses as needed. Visually inspect hoses for cuts, etc. Weekly Wipe down entire unit as needed. Apply good coat of auto wax to all painted surfaces inside and out. Thoroughly clean wand and inspect for clogged jet, debris in vacuum slot and leaking fittings at valve. Apply light coat of auto wax to wand. Thoroughly clean vacuum and high pressure hoses including hose cuffs. 9-5: Machine Maintenance

132 VAN LONG-TERM MAINTENANCE SCHEDULE The following components or systems should be serviced or replaced at the specified intervals. Component Interval (Machine hours / months of service) High pressure water pump rebuild 2,000 / 24 Vehicle engine thermostat 2,000 / 24 Vehicle engine accessory drive belt 2,000 /24 CDS clutch 3,000 / 36 CDS drive shaft 3,000 / 36 CDS blower silencer and exhaust plumbing 4,000 / 48 CDS and vehicle heater hoses 4,000 / 48 CDS wire harness 4,000 / 48 CDS clutch housing drive bearings 4,000 / 48 Machine Maintenance: 9-6

133 DRIVE SHAFT MAINTENANCE Every 500 operating hours, apply lubricant to the drive shaft s zerk fittings at clutch and blower flange U-joints (see Figure 9-1). Figure 9-1. Zerk Fittings on Drive Shaft The drive shaft spline should also be lubricated with a bearing grease with an application temperature range of -4 F to +347 F; the drive shaft manufacturer recommends Mobil Delvac Xtreme Service grease as the lubricant. 9-7: Machine Maintenance

134 TROUBLESHOOTING HEATING SYSTEM 1.0. Vehicle overheats and shuts off CDS Refer to vehicle dealer for diagnosis and repair Vehicle overheats POSSIBLE CAUSE 2.1. Faulty thermostat in vehicle Faulty water pump on vehicle 2.3. Faulty radiator (plugged) limited water flow 2.4. Faulty fan clutch, limited air-flow. Refer to dealer Refer to dealer Refer to dealer Refer to dealer SOLUTION 3.0. Unable to achieve normal cleaning temperature POSSIBLE CAUSE SOLUTION 3.1. There is hard water or This will not allow the heat to transfer properly. Descale chemical build-up in the heat and flush as necessary. See page 9-11 of this Manual for exchangers. the heat exchanger back flush procedure Cleaning solution flow is Measure flow at tool. too great The jet in the cleaning tool is too large or worn out. Test the tool for water flow and replace or repair jet as necessary Cleaning solution pressure is too high. Adjust pressure to normal. Inspect pressure gauge for accurate reading The system thermal valve is stuck open The CDS is being operated at too low rpm or too low vacuum setting. Remove recovery tank lid and check for premature flow from thermal valve hose at tank. The machine must be at or below normal operating temperature for this test. Replace or repair as necessary. The system must be at full operating rpm and full vacuum load to achieve full operating temperature. These values must be set per manufacture s specifications. Adjust vacuum or rpm as necessary. Machine Maintenance: 9-8

135 4.0. System attains normal heat but drops off sharply POSSIBLE CAUSE SOLUTION 4.1. Solution flow at cleaning Test flow of tool. Repair or replace as necessary. tool is too high. Orifice in tool is too large or worn out The rpm of machine is Adjust as necessary. set too low Recirculation orifice Clean filter screen and inspect orifice. Clean or replace plugged, giving incorrect as necessary. reading at gauge Cleaning solution Adjust pressure to normal. Inspect pressure gauge for pressure is too high. accurate reading Hard water deposits are Descale the Flex System as directed (see page 9-10). in the system. Miscellaneous 1.0. Vehicle radiator overflows into coolant overflow container while machine is in use. POSSIBLE CAUSE SOLUTION 1.1. Internal leak in coolant heat exchanger. Pressure test each heat exchanger separately to determine which heat exchanger is faulty. This process requires heated water and high pressure to simulate the same conditions that are causing the leak. Refer to qualified service technician if necessary. 9-9: Machine Maintenance

136 DESCALING FLEX SYSTEM AS REQUIRED 1. With the CDS turned off, remove the fasteners from the QC Dash Box cover panel and lift the cover off of the QC Dash Box. 2. Disconnect and remove the female QC fitting assembly from the QC Dash Box, with the 18 hose still attached, and place the female QC fitting assembly/hose into a large bucket (see Figure 9-2). The descaler will drain from the female QC fitting assembly/hose quickly. Have extra buckets ready to swap out because each bucket should fill quickly. 3. Pour 5 gallons of descaler solution into each of the Flex tanks. 4. Turn on the CDS but do not start it. 5. Turn on Natural Pump #1 and run it until the Flex tank is empty. 6. Add water to the Flex tank to flush all descaler out of the solution line. 7. Turn on Natural Pump #2 and run it until the Flex tank is empty. 8. Add water to the Flex tank to flush all descaler out of the solution line. 9. Turn off the CDS. 10. Re-assemble and re-connect the female QC fitting assembly and 18 hose into the QC Dash Box. 11. Re-install the cover panel onto the QC Dash Box. Machine Maintenance: 9-10

137 BACK FLUSHING HEAT EXCHANGERS Back flushing should be performed every 500 operating hours. It must be performed in addition to descaling. Please note that, although similar, back flushing is not the same as descaling. 1. With the CDS turned off, remove the fasteners from the QC Dash Box cover panel and lift the cover off of the QC Dash Box. 18 Hose Female QC Fittings 18 Hose Cover Removed from QC Dash Box Female QC Fitting Assembly Figure 9-2. Disconnect Female QC Fitting Assembly with 18 Hose Attached 2. Disconnect and remove the female QC fitting assembly from the QC Dash Box, with the 18 hose still attached, and place the female QC fitting assembly/hose into a large bucket (see Figure 9-2). The back flushed hot water will drain from the female QC fitting assembly/hose. Have extra buckets ready to swap out because each bucket should fill quickly. Press the PUMP CLUTCH switch to OFF when swapping buckets to avoid spillage. 9-11: Machine Maintenance

138 3. Connect the garden hose to the CDS fresh water inlet (see Figure 9-3). Turn on the fresh water source (typically, the outdoor water faucet). 4. Start the CDS. 5. Set the THROTTLE CONTROL switch to High (Speed 1) and follow normal warm up procedures. 6. After the CDS is warmed up, press the PUMP CLUTCH switch to ON and set the pressure to 900 psi (see Figure 9-3). Set Pressure to 900 psi Connect Solution Hose Here Connect Garden Hose Here QC DASH BOX Figure 9-3. Set Pressure, and Connect Solution Hose and Garden Hose Machine Maintenance: 9-12

139 7. Press the PUMP CLUTCH switch to OFF momentarily to connect the solution hose. 8. Connect one end of the solution hose to one of the CDS solution out fittings and the other end to the male QC fitting on the QC Dash Box (see Figure 9-3). 9. Press the PUMP CLUTCH switch to ON and run the CDS for 5 minutes, or longer, until the water coming out from the hose into the bucket is clear. 10. After about 5 minutes, press the PUMP CLUTCH switch to OFF and then turn off the CDS. 11. Re-assemble and re-connect the female QC fitting assembly and 18 hose into the QC Dash Box. 12. Re-install the cover panel onto the QC Dash Box. 13. Turn off the outdoor water source and disconnect the solution hose and the garden hose. 9-13: Machine Maintenance

140 CLEAN QC DASH BOX FILTERS AND ORIFICES Clean and inspect the in-line quick connect filters and orifices every 100 hours. 1. With the CDS turned off, remove the fasteners, including the wing nuts, from the QC Dash Box top/left cover panel and lift the cover off of the QC Dash Box. 2. Disconnect and remove the female QC fittings from the 18 hose (see Figure 9-4). 3. Disassemble the QC fittings, remove the filter from each fitting and wash with clean water, removing any debris (see Figure 9-5). 4. With a hex L-key, remove the orifice from each fitting and wash with clean water, removing any debris (see Figure 9-4). 18 Hose Cover Removed from QC Dash Box Female QC Fittings Figure 9-4. Remove Cover from QC Box Filter Orifice Orifice Figure 9-5. Remove Filter and Orifice from Each Fitting 5. Re-assemble the fittings with the filters and orifices, and reconnect the female QC fittings onto the 18 hose. 6. Replace the cover panel onto the QC Dash Box and re-install all the fasteners, including the wing nuts. Machine Maintenance: 9-14

141 PUMP TUNING INSTRUCTIONS Pump tuning for the CTS 4.8 Flex allows the pump pressure switch to turn off when there is no flow out of the tool. This reduces the pump operating temperatures and increases the pump durability. Pump tuning should be performed every 60 days. The pump pressure setting adjustment is performed by turning the hex screw, which is close to the center of the pump head, with a hex L-key, provided in the Flex Installation Kit - (see Figure 9-6). Clockwise increases the pressure Counterclockwise decreases the pressure. CLOCKWISE INCREASES PRESSURE COUNTERCLOCKWISE DECREASES PRESSURE Figure 9-6. Location of Pump s Hex Screw Tools required include: 1/16 hex L-key (one is provided with each pump for your convenience in Installation Kit, P/N ). Solution hose Cleaning tool (upholstery tool/ wand/ rotary cleaning tool) to allow solution to flow out Container to collect solution flowing out of the tool. 9-15: Machine Maintenance

142 Start up Pump Tuning Procedure 1. Connect the tool s solution hose to one of the 2 quick disconnects (the stainless steel low pressure solution ports) on the QC Dash Box (see Figure 9-7). Connect Hose to Either QC Fitting 2. Turn the CDS key to the ON position but do not start the CDS unit (see Figure 9-8). You do not need to start the CDS unit since vacuum is not needed for this procedure. 3. Turn on the driver s side pump (Pump 1) until all air is bled from the system (see Figure 9-8). Figure 9-7. Connect Solution Hose to QC Dash Box Pump Switch Position- #1 ON Position START Position Figure 9-8. CTS 4.8 Flex Dash Panel, Showing Pump Switch Position for Pump #1 Machine Maintenance: 9-16

143 4. With the pump still on, disconnect the solution hose from the Flex unit (see Figure 9-9). The pump should run for about 3 to 5 seconds and then switch off. Disconnect Hose Here 5. Leave the hose disconnected. Continue on to the Adjustment procedure (page 9-18). After the Adjustment procedure has been performed for the driver s side pump (#1 - see page 9-18), repeat the entire procedure for the passenger side pump (#2 - see Figure 9-10), starting with step 1 on page Figure 9-9. Disconnect Solution Hose Then, perform the Adjustment procedure for the passenger side pump. Pump Switch Position - #2 ON Position START Position Figure CTS 4.8 Flex Dash Panel, Showing Pump Switch Position for Pump #2 9-17: Machine Maintenance

144 Adjustment 1. If the pump continues to run for longer than 3 to 5 seconds, turn the screw counterclockwise until the pump switches off (see Figure 9-11). 2. If the pump switches off as soon as the hose is disconnected (less than 3 to 5 seconds), turn the pump screw clockwise one complete turn. 3. With the pump still on, reconnect the solution hose onto the Flex unit (see Figure 9-7). COUNTERCLOCKWISE CLOCKWISE Figure Insert Hex L-Key and Turn It Counterclockwise/Clockwise The pump should switch on. 4. Repeat steps 1 through 3 on this page until the pump switches off within 3 to 5 seconds after the hose is disconnected. 5. Repeat the entire procedure for the passenger side pump, starting with step 1 on page Machine Maintenance: 9-18

145 10 - How to Order Parts To order warranty replacement parts or repairs, it is important that you read this section which includes: Warranty Parts Orders Parts Orders Emergencies WARRANTY PARTS ORDERS 1. Call the local distributor where you purchased your equipment and ask for the Service Department. 2. Have the following information ready: a. Equipment Model b. Date of Purchase c. Hours on the Unit d. Unit Serial Number e. Description of Malfunction 3. Once it has been determined which parts are needed to correct the problem with your machine, make arrangements with your distributor to either perform the repairs or ship the parts to you. PARTS ORDERS Call your local distributor. In most instances, they either stock or have access to parts through a regional service center. EMERGENCIES If, for any reason, your distributor is unable to supply you with the necessary parts, they may call HydraMaster and arrange for expedited shipping. HydraMaster sells parts only through authorized distributors and service centers. Any questions you have regarding the warranty program should be directed to your distributor.. HydraMaster warranty covers only defective materials and/or workmanship for the periods listed. Diagnostic reimbursement is specifically excluded. 10-1: How to Order Parts

146 How to Order Parts: 10-2

147 11 - Warranty Information To avoid misunderstandings which might occur between machine owners and the manufacturer, we are listing causes of component failure that specifically voids warranty coverage. Such causes listed in this section shall constitute abuse or neglect. BLOWER Failure to maintain proper oil levels, or to use the correct oil grade and viscosity as recommended in blower manual. Failure to properly maintain blower safeguard systems such as waste tank filter screen, vacuum safety relief valve and waste tank automatic shut-off system. Allowing foam to pass through blower. HIGH PRESSURE WATER PUMP Failure to maintain proper oil level as recommended in pump manual. Failure to change oil in pump at recommended intervals. Failure to protect pump against freezing. Failure to maintain pump protection shut-off system. Failure to use water softener in hard water areas. Use of improper chemicals. RECOVERY TANK Failure to properly maintain filtering devices in tank. Failure to clean tank as recommended by manufacturer. Failure to maintain vacuum safety release in tank. Use of improper chemicals. CHEMICAL SYSTEM Use of improper chemical. Operating machine without proper chemical filter screen. Failure to protect against freezing. CONTROL PANEL Failure to protect flowmeter and water pressure gauge against freezing. 11-1: Warranty Information

148 VACUUM AND SOLUTION HOSES Failure to protect hoses against freezing. Failure to protect hoses against burns from engine and blower exhaust. Damage to hoses from being run over by vehicles. Kinking or cracking from failure to store or unroll hoses correctly. Normal wear and tear from everyday use. CLEANING WAND AND TOOL Failure to protect against freezing. Obvious physical abuse of wand or tool. WATER HEATING SYSTEM Over-pressurization of the system (recommended maximum working pressure - 1,200 psi). Failure to protect against freezing. HARD WATER DEPOSITS Failure to use or maintain a water softening system or a properly installed magnetictype descaler, whichever might be necessary, with machines operating in designated Hard Water Areas (3.5 grains or more per gallon). Warranty Information: 11-2

149 WARRANTY PROCEDURE Warranty coverage is available to you through your local distributor. When calling your distributor, be sure to have the machine s information; model and serial number, ready for the service representative. FOR YOUR REFERENCE:. Model No. Serial No. Date of Purchase: Purchased From (Distributor): 11-3: Warranty Information

150 Warranty Information: 11-4